Method and apparatus for a product settler

ABSTRACT

A method and apparatus for settling a product in a package made on a form, fill and seal machine. In one aspect the invention comprises the steps: providing a package material on a product conduit of a form, fill and seal machine; forming a first end seal on the package material to form a partially formed package; filling the partially formed package with product; and settling the product in the partially formed package while continuously conveying the package material along the product conduit. In a second aspect, the invention comprises a product settler comprising a first object positioned to cause an impact against a package material. The impact agitates the package material and settles a product from an unsettled height to a settled height while the package material is continuously conveyed.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application is a continuation-in-part of and claims priorityto U.S. Nonprovisional patent application Ser. No. 14/581,013, entitled“Method and Apparatus for a Product Settler,” filed Dec. 23, 2014, andpublished as US 2016/0176548 A1 on Jun. 23, 2016, and U.S.Nonprovisional patent application Ser. No. 14/581,110, entitled “Methodand Apparatus for a Product Settler,” filed Dec. 23, 2014, and publishedas US 2016/0176549 A1 on Jun. 23, 2016, all of which are herebyincorporated by reference in their entirety as examples.

BACKGROUND OF THE INVENTION Technical Field

The present invention relates to an apparatus and method for settlingproducts in a package.

Background

Many foodstuffs, such as potato chips, are packaged in pillow pouchpackages that are made using a form, fill and seal (“FFS”) machine.Typically, a form, fill and seal machine forms the film into a tube,seals the bottom of the tube, fills the partially sealed tube withproduct, and then seals the top of the tube to form a packaged product.Often, a form, fill and seal machine is oriented so that film travels ina direction that is generally vertical as the film is formed into atube, filled with product and sealed. Such a machine is an example of avertical form, fill and seal (“VFFS”) machine.

When the product being packaged is an irregularly shaped product such aspotato chips, there can be large void spaces between each piece. Thevoid space takes up volume in the package and requires the package to belarger than required for the product alone. This requires moreresources, which is less environmentally friendly. It is also moreexpensive for producers and ultimately consumers.

To avoid these and other problems posed by void space, some form, filland seal machines are fitted with product settlers. These settlerstypically shake the product to make it settle into a more compactconfiguration and thereby reduce void space.

In addition to reducing void space in a product, it is desirable topackage product more quickly. One way to increase the speed with whichproduct is packaged is to increase the speed with which film is fed tothe form, fill and seal machines. Other things being equal, continuouslyfeeding film to a machine is faster than intermittently feeding film.

To take advantage of this principle, some machines, called continuousmotion machines, are capable of running in a continuous mode in whichfilm is continuously being advanced, as opposed to being pausedintermittently. However, running a machine in continuous mode isincompatible with conventional settlers that grab or pinch the film.This is because grabbing or pinching will damage the film unless thefilm is paused.

Examples of conventional settlers that require a film to be pausedinclude settlers with beater bars that grab and shake the film. Anotherconventional settler that requires film to be paused uses two swingingpanels. The two panels are positioned below the product conduit and canrotate together like doors. When the panels come together, they pinchand seal off the film below the product conduit. After product falls onthe closed panels, seal jaws come together to form an end seal on thefilm. This forms the bottom of a partially formed package. Then, thepanels rotate open, which releases the film and allows the product tofall to the bottom of the partially formed package. This process ofrepeatedly dropping and catching the product causes the product to besettled. However, it can also damage the product by causing breakage,for example, of chips.

As these examples illustrate, when using conventional settlers, form,fill and seal machines must run in an intermittent mode in which thefilm is stopped when the settlers grab the film, and the film advanceswhen the settlers release the film. As a result, many continuous motionmachines do not even come with a settler. Other machines come with asettler that can be installed by a user, but the machine must then berun in an intermittent mode. Running machines in intermittent mode isinefficient and results in additional wear and tear on the machines andfilm. Thus, using a conventional settler with a continuous motion form,fill and seal machine can be undesirable.

Accordingly, it would be advantageous to have a settler that iscompatible with a form, fill and seal machine running in continuousmode. For example, it is desirable to have a settler that does not grabfilm and can be used with a machine that continuously conveys the film.Such a settler would not require the film to be paused during productionof packages. This could, in turn, avoid wear and tear on the machine andfilm caused by large transient forces that occur when starting andstopping the machine.

It would also be advantageous if an inventive settler could be used toproduce product-filled packages more quickly than conventional settlersthat require packaging film to be paused intermittently.

In addition, it would be desirable if the inventive settler reduced thevolume that product occupies in a package. For example, it would bedesirable if the settler reduced the volume occupied by a product atleast as much as a conventional settler.

Furthermore, it would be desirable if an inventive settler couldincrease the head space in a package of a given size. For example,increased head space can help prevent product inside the package frombeing too close to, or caught in, the end seal of the package. Thishelps to ensure that the package is properly sealed. Increased headspace can also help prevent other manufacturing defects, for example,unintended pleats and unintended tucks. It would be even more desirableif the inventive settler could increase head space and/or reducemanufacturing defects when compared to conventional settlers.

Likewise, it would be beneficial if the inventive settler did not breaka substantial amount of product by impacting the product. For example,it would be beneficial if the settler were positioned so that it did notimpact a substantial amount of the product through the packaging film.It would also be advantageous if the inventive settler could optionallybe mounted somewhere besides the seal jaw carriage of a form, fill andseal machine. As another example, it would be beneficial if theinventive settler could operate intermittently or continuously. Forexample, it would be beneficial if the inventive settler could stopsettling while the product is in a position to be damaged by thesettler. However, after the product is no longer in such a position, theinventive settler would begin settling again.

Similarly, it would be desirable if the inventive settler decreased theamount of film required to package a given amount of product. This couldhelp reduce waste, increase the environmental friendliness of a process,reduce manufacturing costs, and further increase the speed of amanufacturing process. For example, using a settler that can be usedwith a continuous motion form, fill and seal machine can increase thespeed of a manufacturing process. Also, if the inventive settler coulddecrease the amount of film necessary to package a product, less filmwould need to be conveyed for a unit of product. This could furtherreduce the amount of time required to produce each unit.

In addition, it would be advantageous if the inventive settler did notinterfere with the continuous motion of a package film when theinventive settler stopped. For example, it would be advantageous if theinventive settler had a low torque motor so that if the settler stoppedrunning or even failed while the settler was in contact with a packagefilm, the film could push the settler out of the path of the film, andthe film could continue to be advanced. It would also be advantageous ifthe inventive settler could be stopped in a position where it does notimpede the continuous conveyance of packaging film.

It would be another benefit if the inventive settler were simplecompared to conventional settlers. For example, it would be beneficialif the inventive settler had fewer moving parts than conventionalsettlers, had a less complicated operating mechanism, and were easier tomaintain, repair and/or replace. It would also be beneficial if theinventive settler required minimal training of or input from maintenancepersonnel.

Furthermore, it would be useful if the inventive settler were smallcompared to conventional settlers. For example, conventional settlerscan have components that take up a large amount of space and it would beadvantageous to avoid these components.

Additionally, it would be desirable if the inventive settler could beeasily installed on existing form, fill and seal machines. For example,it would be desirable if the inventive settler were modular and could beeasily added to existing continuous motion vertical form, fill and sealmachines. It would also be useful if a modular form of the inventivesettler were easier to maintain, repair, and/or replace thanconventional settlers. For example, it would be desirable if aninventive settler needing maintenance could be easily removed from acontinuous motion form, fill and seal machine and replaced with arecently serviced settler. It would also be desirable if the inventivesettler were designed so that the form, fill and seal machine could runwithout needing to be substantially reconfigured if the inventivesettler were removed and were not replaced. For example, the machinecould be instructed to create bigger packages due to a lack of settling,but the machine would not require other reconfiguration. This couldincrease the versatility of a product manufacturing line and increaseits resilience in the face of maintenance issues.

Similarly, it would be advantageous if a form, fill and seal machinewere easier to maintain and repair when the inventive settler is usedwith the machine instead of a conventional settler. It would also beadvantageous if the small size and location of the inventive settlermade it easier to access and service the machine compared toconventional settlers. For example, the size and location ofconventional settlers can block or substantially impede access to theseal jaw carriage of a form, fill and seal machine. In contrast, itwould be advantageous if the inventive settler could be installed on oneside of a machine making it easy to access the seal jaw carriage evenwhen the inventive settler is installed. It would also be advantageousif the inventive settler could easily be removed in comparison to aconventional settler, for example, if the inventive settler weremodular, as this would also increase the ease of servicing of form, filland seal machine.

SUMMARY OF THE INVENTION

The present invention is a method and apparatus for settling products.For example, the inventors have developed a new type of settler that canbe used in conjunction with a form, fill and seal machine even when themachine is running in continuous mode.

In a first aspect, the invention provides a method for settling aproduct in a package made on a form, fill and seal machine. The methodcomprises the steps: providing a package material on a product conduitof a form, fill and seal machine; forming a first end seal on thepackage material to form a partially formed package; filling thepartially formed package with product; and settling the product in thepartially formed package while continuously conveying the packagematerial along the product conduit.

In a second aspect, the invention provides an apparatus comprising animproved continuous motion form, fill and seal machine. The machinecomprises a product conduit, a conveyor, and seal jaws. The conveyor ispositioned to convey a package material that is wrapped around theproduct conduit, and the conveyor moves the package material along theproduct conduit. The seal jaws are positioned adjacent to oppositeportions of the package material to form a first end seal on the packagematerial, thereby forming a partially formed package. The productconduit is positioned so that a product passing through the productconduit will enter the partially formed package after exiting theproduct conduit, and the product conduit is positioned above the sealjaws. The improvement comprises a product settler comprising a firstobject positioned to cause an impact against the package material. Theimpact agitates the package material and settles the product from anunsettled height to a settled height while the machine continuouslyconveys the package material along the product conduit.

In a third aspect, the invention provides a method for settling aproduct in a partially formed package. The method comprises the steps:providing a partially formed package; filling the partially formedpackage with a product; and settling the product in the partially formedpackage. The settling step comprises rotating a paddle wheel comprisingat least one paddle against the partially formed package.

In a fourth aspect, the invention provides an apparatus comprising animproved product settler for settling product in a partially formedpackage. The improved product settler comprises a paddle wheel. Thepaddle wheel comprises at least one paddle that is positioned to causean impact against the partially formed package. The impact agitates thepartially formed package and thereby settles the product.

The invention described herein provides many advantages in its variousembodiments. In one aspect, the invention provides a settler that iscompatible with a form, fill and seal machine running in continuousmode. For example, it provides a settler that does not grab film and canbe used with a machine that continuously conveys the film. Such asettler does not require the film to be paused during the production ofpackages. This, in turn, avoids large transient forces that occur whenstarting and stopping the machine and avoids associated wear and tear onthe machine. In one embodiment, the inventive settler comprises arotating paddle wheel with a paddle that impacts the film insubstantially the same direction that the film is conveyed. Accordingly,in one embodiment, the inventive settler comprises paddles thatintermittently contact the film and scrub the film in the film'sdirection of conveyance.

The inventive settler also can be used to produce product-filledpackages more quickly than conventional settlers, which requirepackaging film to be paused intermittently.

In addition, the inventive settler can reduce the volume that productoccupies in a package. For example, the settler reduces the volumeoccupied by a product at least as much as a conventional settler.

Furthermore, the inventive settler increases the head space in a packageof a given size. For example, increased head space can help preventproduct inside the package from being too close to, or caught in, theend seal of the package. This helps to ensure that the package isproperly sealed. Increased head space can also help prevent othermanufacturing defects, for example, unintended pleats and unintendedtucks. Additionally, the inventive settler can increase head spaceand/or reduce manufacturing defects when compared to conventionalsettlers.

As another advantage, the inventive settler does not break a substantialamount of product by impacting the product. In one embodiment, theinventive settler causes little or no breakage of product. For example,the settler can be positioned so that the settler does not impact asubstantial amount of the product through the packaging film when thesettler is in operation. In one embodiment, the inventive settler can bemounted somewhere besides the seal jaw carriage of a form, fill and sealmachine. For example, the settler can be positioned just below theproduct conduit of a form, fill and seal machine so that the settlerdoes not impact a substantial amount of product as the product fallsfrom the product conduit and into the packaging film. The inventivesettler can also operate intermittently or continuously. For example,the inventive settler can stop settling while the product is in aposition to be damaged by the settler. However, after the product is nolonger in such a position, the inventive settler can begin settlingagain.

The inventive settler can also decrease the amount of film required topackage a given amount of product. This helps reduce waste, increase theenvironmental friendliness of the process, reduce manufacturing costs,and further increase the speed of a manufacturing process. For example,the inventive settler can be used with a continuous motion form, filland seal machine which increases the speed of a manufacturing processrelative to using an intermittent machine. Also, although conventionalsettlers cannot be used with continuous motion machines, the inventivesettler can. Accordingly, the inventive settler can decrease the amountof film necessary to package a product on a continuous motion machine.Since less film needs to be conveyed for a unit of product, this furtherreduces the amount of time required to produce each unit.

In addition, the inventive settler does not interfere with thecontinuous motion of a package film when the inventive settler stops.For example, the inventive settler has a low torque motor so that if thesettler stops running or even fails while the settler is in contact witha package film, the film can push the settler out of the path of thefilm, and the film can continue to be advanced. As another example, theinventive settler can be stopped in a position where it does not impedethe continuous conveyance of packaging film.

The inventive settler is also simple compared to conventional settlers.For example, compared to conventional settlers, the inventive settlerhas fewer moving parts, has a less complicated operating mechanism, iseasier to maintain, is easier to repair and/or is easier to replace. Theinventive settler also requires minimal training of and input frommaintenance personnel.

Furthermore, the inventive settler is small compared to conventionalsettlers. For example, conventional settlers can have components thattake up a large amount of space and the inventive settler advantageouslyavoids this.

Additionally, the inventive settler can be easily installed on existingform, fill and seal machines. For example, in one embodiment, theinventive settler is modular and can be easily added to existingcontinuous motion vertical form, fill and seal machines. Also, theinventive settler is easier to maintain, repair, and/or replace thanconventional settlers. For example, a modular form of the inventivesettler can be installed, uninstalled, and serviced with ease. Asanother example, the inventive settler can be easily removed from acontinuous motion form, fill and seal machine and replaced with anotherinventive settler. Also, the inventive settler is designed so that theform, fill and seal machine can run without needing to be substantiallyreconfigured if the inventive settler is removed and is not replaced.For example, the machine can be instructed to create bigger packages dueto a lack of settling, but the machine does not require otherreconfiguration to continue producing product. Accordingly, theinventive settler increases the versatility of a product manufacturingline and increases its resilience in the face of maintenance issues.

Similarly, a form, fill and seal machine is easier to maintain andrepair when the inventive settler is used with the machine instead of aconventional settler. In one embodiment, the small size and location ofthe inventive settler during operation make the machine easier to accessand service when compared to machines using conventional settlers. Forexample, the size and location of conventional settlers can block orsubstantially impede access to the seal jaw carriage of a form, fill andseal machine. In contrast, the inventive settler can be installed on oneside of a machine, rather than, for example, having components that areadjacent to opposite sides of the machine. For example, the inventivesettler can comprise a paddle wheel that is positioned adjacent to oneside of a product conduit of a form, fill and seal machine. Accordingly,when the inventive settler, as opposed to a conventional settler, isinstalled on a machine, it is easier to access the components (e.g.,seal jaw carriage) of the machine. Furthermore, the inventive settlercan easily be removed in comparison to a conventional settler. When theinventive settler is modular, this further increases the ease ofservicing a form, fill and seal machine when compared to servicing amachine using a conventional settler.

Another benefit of the inventive settler is that it can be used tosettle many different kinds of products. For example, the inventivesettler is especially useful for settling larger or irregularly shapedproducts such as tortilla chips or potato chips. The settler is alsouseful for settling smaller or regularly shaped products such asCheetos® cheese puffs. Although, when compared to larger or irregularlyshaped products, smaller or regularly shaped products may experienceless settling.

Other aspects, embodiments and features of the invention will becomeapparent from the following detailed description of the invention whenconsidered in conjunction with the accompanying drawings. Theaccompanying figures are schematic and are not intended to be drawn toscale. In the figures, each identical or substantially similar componentthat is illustrated in various figures is represented by a singlenumeral or notation. For purposes of clarity, not every component islabeled in every figure. Nor is every component of each embodiment ofthe invention shown where illustration is not necessary to allow thoseof ordinary skill in the art to understand the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

The novel features believed characteristic of the invention are setforth in the appended claims. The invention itself, however, as well asa preferred mode of use, further objectives and advantages thereof, willbe best understood by reference to the following detailed description ofillustrative embodiments when read in conjunction with the accompanyingdrawings, wherein:

FIG. 1 is a flow chart depicting one embodiment of a process accordingto the invention;

FIG. 2 is a schematic view of one embodiment of the invention for usewith a vertical, form, fill, and seal machine;

FIGS. 3A-3C are a progression of schematic views of one embodiment ofthe invention depicting a product settler being used to settle product;

FIGS. 4A-4B are schematic depictions of a package for product that canbe settled by one embodiment of the invention;

FIG. 5A is a schematic top view of one embodiment of the invention;

FIG. 5B is a schematic side view of the embodiment shown in FIG. 5A;

FIG. 5C is a schematic front view of the embodiment shown in FIG. 5A;

FIGS. 6A-6C are schematic perspective views depicting one embodiment ofa product settler;

FIG. 7 is a schematic view of one embodiment of the invention for usewith a vertical, form, fill, and seal machine;

FIG. 8 is a schematic side view depicting, from left to right, aprogression of scenes illustrating how an embodiment of a productsettler impacts a partially formed package to settle product within thepartially formed package;

FIG. 9 is a schematic illustration useful for characterizing theflexibility or rigidity of a paddle of a product settler and depictinghow any bend that occurs in the paddle during use can be measured, forexample, with the aid of a camera or other imaging device, and limitedto a specified bend tolerance;

FIGS. 10-11 are schematic perspective views depicting one embodiment ofa product settler in which a rotor for a motor of the product settleralso acts as an axle for a paddle wheel of the product settler;

FIG. 12 is a schematic view of one embodiment of a product settler foruse with a vertical, form, fill, and seal machine and illustrating aproduct settler with concentric axes of rotation for a rotor and apaddle wheel;

FIG. 13 is a schematic view of one embodiment of a product settlerdepicting a reference motor cylinder provided with the smallest radiusthat enables the reference motor cylinder to contain a motor of theproduct settler and depicting a reference paddle wheel cylinder providedwith the smallest radius that enables the reference paddle wheelcylinder to contain a paddle wheel of the product settler;

FIG. 14 is a schematic view of a product settler with a paddle wheel inwhich adjacent paddles are mutually oriented at a paddle spacing angleand illustrating how the paddle spacing angle can vary among the pairsof adjacent paddles.

DETAILED DESCRIPTION

Several embodiments of Applicant's invention will now be described withreference to the drawings. Unless otherwise noted, like elements will beidentified by identical numbers throughout all figures.

One embodiment of the invention will now be described with respect toFIGS. 1, 2, 3A-3C, and 4A-4B. The embodiment is a method for settling aproduct in a package 404 made on a form, fill and seal machine. Themethod comprises the following steps. First, in a providing step 102, afilm 202 is provided on a product conduit 204 of a form, fill and sealmachine 206 (e.g. a vertical form, fill and seal machine).

Second, in a longitudinal sealing step 104, the film 202 is sealed toform a longitudinal seal 402 (e.g. back seal) on a package 404. FIGS.4A-4B depict a package 404 with a first face (e.g., first end 414 or abottom 414), a second face (e.g., a second end 416 or a top 416), athird face 408 (e.g., a front face), a fourth face 406 (e.g., a backface), a fifth face 410 (e.g., a right face), and a sixth face 412(e.g., a left face). An example of a longitudinal seal 402 (e.g., a backseal) can be seen on the fourth face 406 (e.g., back side) of thepackage 404. The longitudinal seal 402 can be useful to form a tube 210from a film 202 that has been wrapped around a product conduit 204(e.g., a hollow former). As shown, the tube 210 has a continuouscircumference 218. Although a longitudinal seal 402 is provided in someembodiments, in other embodiments, a longitudinal seal is not provided.Accordingly, the longitudinal sealing step 104 is optional. When alongitudinal sealing step 104 is not used to provide a tube-shaped film210, the tube-shaped film can be provided in other ways, for example, byusing a process to produce a blown film, which can have a continuouscircumference 218 without using a longitudinal sealing step 104.

Third, in a first end-sealing step 106, a first end seal 212 a is formedon the film 202 to form a partially formed package (e.g., partiallyformed second package 404 b in FIG. 2). The first end seal 212 a islocated on a first face (e.g., first end 414) of the partially formedpackage. As can be seen in FIG. 2, a first package 404 a has alreadybeen formed and a second package 404 b is a partially formed package.However, before the first package 404 a was formed, it was also apartially formed package (e.g., partially formed second package 404 b).

Fourth, in a filling step 108, the partially formed package (e.g.,partially formed package 404 b) is filled with a product 302. An exampleof how a package 404 b can be filled with product is illustrated inFIGS. 3A-3B. The product 302 enters the package 404 b through theproduct conduit 204. As the product enters the package, it moves in afill direction 304, and the product 302 falls under the force ofgravity. Accordingly, as shown, the fill direction 304 is downward,although other fill directions are also possible.

Fifth, in a settling step 110, the product 302 in the package (see,e.g., partially formed second package 404 b in FIGS. 3A-3B) is settledwhile the film 202 is continuously conveyed along the product conduit204 in a direction of conveyance 306. In one embodiment, the packagematerial is continuously conveyed at a location where the packagematerial is formed into a package (or partially formed package).Additionally, as shown in FIG. 2, the film is continuously conveyed in adirection of conveyance 306 at the product conduit 204, but the film canalso be conveyed in a different direction of conveyance 307 at anotherlocation.

FIGS. 3A-3C illustrate how product 302 is settled in a partially formedpackage 404 b. In one embodiment, the inventive settler includes apaddle wheel that rotates and contacts (e.g., scrubs) a package film inthe direction of the film's conveyance. The contact between the paddlewheel and the film causes the film to shake and thereby settles productinside the film.

FIG. 3A shows a package 404 b being filled with the product 302 underthe force of gravity. FIG. 3B illustrates how the product 302 hasaccumulated at the first end 414 of the partially formed package 404 b.A product settler 308 is actuated to cause the product 302 to settleinto a more compact configuration as shown in FIG. 3C. As shown in FIG.3B the product settler settles the product so that it requires lesslongitudinal space in the partially formed package 404 b. For example,in one embodiment, before settling, the first end of a package is at afirst-end product line 310 and the product is longitudinally distributed(e.g., in a longitudinal direction along central axis 334) in thepackage from the first-end product line 310 to an unsettled second-endproduct line 314 (e.g., unsettled level or height of the product).However, after settling, the product 302 settles to a settled second-endproduct line 312 (e.g., settled level or height of the product).Accordingly, the unsettled package film length 316 required for theunsettled product 302 is greater than the settled package film length318 required for the settled product 302. For example, as shown in FIGS.3A and 3B, the unsettled package film length 316 is the distance fromthe first-end product line 310 to the unsettled second-end product line314 of the product 302. Similarly, the settled package film length 318is the distance from the first-end product line 310 to the settledsecond-end product line 312 of the product 302. Although the settled andunsettled package film lengths indicate the length of film required fora column of product, the overall package length can be greater, forexample, to accommodate folds, gussets, seals, and any desired headspace.

In some embodiments, the settled package film length 318 required forsettled product is about 0.5 to about 1.0 inches shorter than theunsettled package film length 316 required for unsettled product.Accordingly, in some embodiment, the settler can reduce overall packagelengths for a product by about 0.5 to about 1.0 inches.

In some embodiments, the settler 308 settles product 302 while theproduct is falling. In other embodiments, the settler 308 settlesproduct 302 after the product has fallen. In some embodiments, thesettler 308 settles product 302 while the product is falling and afterthe product has fallen. In some embodiments, the settler 308 comprises apaddle (e.g., one of a plurality of paddles 320 a,b) that rotates in arotational direction 322 so that when the paddle contacts the film 202,the paddle pushes the film generally in the direction of conveyance 306of the film.

Sixth, in a second end-sealing step 112, a second end seal 212 b isformed on the partially formed package 404 b to form a package 404 a.The second end seal 212 b is located on a second face of the package(e.g., second end 416 of the first package 404 a). This can be seen, forexample, in FIG. 2.

In the illustration shown in FIGS. 4A-4B, the first end seal 212 a isapproximately perpendicular to the longitudinal seal 402 (e.g., a backseal).

In one embodiment, the settling step 110 comprises the step ofintermittently contacting the package (e.g., the partially formed secondpackage 404 b in FIG. 2) to move the package, thereby moving the product302 in the package and causing the product to settle.

In one embodiment, the settling step further comprises the step ofintermittently applying a force to the film (e.g., by impacting orcontacting the film) that does not pause the conveyance of the film. Forexample, the component of the force that is opposed to the conveyance ofthe film is not sufficient to pause the conveyance of the film.

In one embodiment, the settling step 110 further comprises the steps ofcontinuously or intermittently rotating a paddle wheel 326 thatcomprises a paddle (e.g., paddle 320 a or paddle 320 b). The paddle isrotated into contact with the package (e.g., second package 404 b inFIG. 3A), thereby moving the product 302 inside the package. In additionto using a paddle wheel to intermittently contact the package film,other objects and mechanisms (e.g., a single bar that moves into and outof contact with the film) can also be used to intermittently contact thefilm.

In one embodiment, gas is directed into the partially formed package 404b. For example, some form, fill and seal machines 206 use pressurizedgas to maintain positive pressure inside the package 404 b. Such amachine can also be used in conjunction with the inventive settler. Forexample, when pressured gas is used, it can be directed in the falldirection 304 shown in FIG. 3A. The gas pressurizes the inside of thepackage 404 b. This pressure provides some structural rigidity to thepackage 404 b and provides resistance to the paddle (e.g., one of aplurality of paddles 320 a,b) when the paddle impacts the film 202 ofthe package 404 b. Upon impact, the paddle pushes the film 202 inward.However, after the impact, there is a period of time before the paddleagain impacts the film. During the period of time between impacts, thepressure of the gas inside the package 404 b provides a force (e.g.,force 324 in FIG. 3B) to push the film 202 out before it is againimpacted by a paddle 320 a,b. The cycle of film being pushed in byimpact from the paddle and the film being pushed out by the pressurefrom the gas causes the film to vibrate (e.g., shake or oscillate),which in turn, causes the product 302 inside the partially formedpackage 404 b to settle (e.g., in a longitudinal direction along centralaxis 334). This cycle is shown with reference to the partially formedpackage 404 b in FIGS. 3B-3C. Although, this cycle has been described inthe context of using a pressurized gas to return the film to an originalposition after the film is deformed by impact, in other embodiments, thefilm may be sufficiently elastic to return to an original position evenwithout using the pressurized gas.

In one embodiment, gas is directed (e.g., in the fill direction 304)into the package (e.g., partially filled second package 404 b in FIG.3A) in the form of a first jet of gas (e.g., air). In one embodiment,the first jet is directed into the package 404 b intermittently. Forexample, in one embodiment, the first jet is activated 520 millisecondsafter a first end seal is formed on the package. The first jet is activefor 1465 milliseconds and then becomes inactive. Additionally, in oneembodiment, a plurality of jets are directed into the package. Forexample, a second jet of gas (e.g., air) can be directed (e.g., in thefill direction 304) into the package 404 b. In some embodiments, thesecond jet is directed into the package 404 b intermittently. Forexample, in one embodiment, the second jet is activated 120 millisecondsafter the first jet becomes inactive. The second jet is active for 1465milliseconds and then becomes inactive.

In one embodiment, the paddle wheel 326 rotates continuously. In anotherembodiment, the paddle wheel 326 rotates intermittently. When the paddlewheel 326 rotates intermittently, the paddle (e.g. paddle 320 a orpaddle 320 b) also rotates intermittently. In one embodiment, a paddlerotates intermittently in the sense that an actuator (e.g., motor 616 inFIGS. 6B-6C) continuously rotates the paddle for a first period of time(e.g., 1500 milliseconds and then the actuator is inactive for a secondperiod of time (e.g., 750 milliseconds). In one embodiment, after theactuator 616 rotates the paddle, the actuator stops the paddle in adesired position (e.g., so that the paddle is not in contact with thefilm). In one embodiment, the actuator 616 actively accelerates thepaddle to increase or decrease its angular velocity. In anotherembodiment, the actuator only actively accelerates the paddle toincrease its angular velocity and the paddle is allowed to deceleratepassively (e.g., due to frictional forces). In some embodiments, thepaddle wheel rotates at about 600 to 700 revolutions per minute (rpm),at about 660 rpm, or at about 600 rpm.

One embodiment of the invention will now be described with reference toFIGS. 2, 3A-3C, 5A-5C, 6A-6C, and 7. For example, FIG. 2 depicts anapparatus comprising an improved product settler 308 for use with acontinuous motion form, fill, and seal machine 206. The form, fill, andseal machine comprising a product conduit 204, a conveyor (e.g., pullbelts 214 a,b), and seal jaws 216 a-d. The continuous motion form, filland seal machine is continuous in the sense that a package film 202 iscontinuously conveyed along a product conduit 204. For example, theconveyor 214 a,b is positioned to convey (e.g., positioned to contact)the package film 202 that is wrapped around the product conduit 204. Theconveyor 214 a,b continuously moves the package film 202 along theproduct conduit 204. The seal jaws 216 a-d are positioned adjacent toopposite portions (e.g., faces 408, 406 in FIGS. 4A-4B) of the packagefilm 202 to form a first end seal 212 a on the package film when theseal jaws 216 a-d move together and the package film is pressed betweenthe seal jaws. This forms a first end seal 212 a on a first face 414 ofa package (e.g., partially formed second package 404 b). The productconduit 204 is positioned so that a product (e.g., product 302 in FIGS.3A-3C) passing through the product conduit will enter the package (e.g.,second package 404 b) after exiting the product conduit. The productconduit 204 is positioned higher than (e.g., above) the seal jaws 216a-d.

As seen in FIG. 2 and FIG. 7, a first seal jaw 216 a rotates around afirst axis of rotation 220 a, and a second seal jaw 216 b rotates arounda second axis of rotation 220 b. Additionally, a third seal jaw 216 crotates around the first axis of rotation 220 a, and a fourth seal jaw216 d rotates around the second axis of rotation 220 b. As the first andsecond seal jaws 216 a,b rotate, they come together to seal and cut thepackage film 202 (e.g., to form a first end seal 212 a on the packagefilm). As shown in FIG. 7, as the seal jaws rotate a sealing face 217 ofeach seal jaw 216 a-d faces the package film 202 and the package film ispressed between seal jaws 216 a-d to form a seal. Likewise, as thesecond and third seal jaws 216 c,d rotate, they come together to sealand cut the package film 202 (e.g., to form a second end seal 212 b onthe package film). In some embodiments, for example, as shown in FIG. 2,a second end seal 212 b for a first package 404 a is formedsimultaneously with a first end seal 212 a for a second package 404 b.

As shown in the embodiment of FIG. 7, the first seal jaw 216 a and thirdseal jaw 216 c are fixed to a first rotating seal jaw carriage 220 a.Similarly, the second seal jaw 216 b and fourth seal jaw 216 d are fixedto a second rotating seal jaw carriage 220 b. As shown in FIG. 2, theseal jaws 216 a-d rotate in a direction 222 a,b so that when the sealjaws 216 a-d contact the package film 202, the seal jaws have atranslational velocity that is generally parallel to a direction ofconveyance 306 of the package film. This is advantageous as it permitsthe package film 202 to continuously move in the direction of conveyancewhile the seal jaws 216 a-d seal and cut the package film 202 to formpackages (e.g., package 404 a). This is an example of a continuous form,fill and seal machine 206. In one embodiment, a form, fill and sealmachine produces at least about 25 packages (e.g. package 404 or package404 a) per minute. In one embodiment, a form, fill and seal machineproduces at least about 40 packages per minute.

Generally speaking, because the inventive settler does not pause apackage film, the number of packages per minute that a machine produceswith the inventive settler is greater than the number of packages perminute that a machine produces when using a conventional settler. Forexample, the speed at which packages of product are produced can dependon the speed at which a film is conveyed for forming a package, thespeed at which the package is filled with product, and any pause inconveying the film that is required to settle a product. If a packagecan be filled with product faster than the film can be conveyed intoposition to form a package, the limiting factor for producing a packageof product is the speed at which the film is conveyed. Furthermore, iffilm speed is the limiting factor for the rate at which packages of aproduct can be manufactured, pausing the film during the activation of aconventional settler will further reduce the number packages per minuteproduced. Thus, when film speed is the limiting factor for a machine'srate of package production and settling is desired, settling with theinventive settler will result in an increased rate of package productionwhen compared to settling with a conventional settler.

Accordingly, the product settler 308 is especially useful in conjunctionwith continuous, form, fill and seal machines because the productsettler does not require the package film 202 to stop in order to settleproduct 302 in the package film. Although the product settler 308 hasbeen described with reference to a continuous form, fill and sealmachine, the product settler can also be used with machines thatintermittently advance the package film 202. An example is any form,fill and seal machine that that stops or pauses the film 202 of apackage 404 a while the package 404 a is being formed. Although apartially formed package has been described with reference to a packagethat has been made on a form, fill and seal machine, this is only anillustrative example.

As another example, the product settler can be used to settle product ina package that is open. For example, a partially formed package can bean open package and the formed package can be the closed package.Although using a product settler on a package that is open, butotherwise formed, may not result in savings related to package materials(e.g., film or paper), it can still provide other benefits. For example,it can decrease the size of the package and reduce costs associated withshipping, including secondary packaging costs for items such as shippingcrates.

With reference to FIGS. 3A-3C, a product settler 308 is positioned toagitate a product 302 in the package film 202. The product settler 308comprises a first object (e.g., paddle 320 a,b) positioned to cause animpact against the film 202. The impact agitates the film 202 andsettles the product 302 from an unsettled height 314 to a settled height312 while a form, fill and seal machine 206 continuously conveys thefilm along the product conduit 204. The impact against the film can becaused directly or indirectly by the first object.

An example of an object directly impacting the film is shown in FIGS.3A-3C. As shown, the product settler 308 comprises a rotatable paddlewheel 326 and the paddle wheel comprises a paddle (e.g., one of aplurality of paddles 320 a,b). The paddle is positioned so that, as thepaddle wheel 326 rotates, the paddle causes agitation of the product 302and thereby settles the product. In the example shown in FIGS. 3A-3C,the paddle intermittently contacts the package film 202 thereby causingagitation of the product 302.

In some embodiments, a first object (e.g., paddle 320 a) is positionedto intermittently and directly contact the package film 202 and thefirst object thereby agitates the product 302. In other embodiments, thefirst object (e.g., paddle 320 a) is positioned to intermittently anddirectly contact a second object (e.g., the product conduit 204), andthe second object contacts the product film 202 and thereby agitates theproduct 302.

As shown in FIGS. 3B-3C, the product settler 308 can be positionedadjacent to a tube of film 202, below the product conduit 204, and abovethe unsettled second-end product line 314. For example, this can providesettling of a product without resulting in breakage of the product. Therisk of breakage can be further reduced by running the product settlerintermittently. For example, the product settler can be paused whileproduct is falling and actuated after the product has fallen past theproduct settler.

In one embodiment, the package film 202 comprises an impact face (e.g.,back side 406 in FIG. 4B). The impact face 406 is adjacent to theproduct settler 308, as shown, for example, in FIGS. 3A-3C. When theimpact face 406 of the package film 202 hangs under the force of gravity(which as shown in FIGS. 3A-3C is the same as the direction ofconveyance 306), the impact face defines a first position of the impactface (e.g., as shown in FIG. 3A). The settler 308 is positioned so thatas the paddle (e.g., paddle 320 a) rotates, a first tip 328 of thepaddle will reach past the first position by a first distance 330. Inone embodiment, as the paddle (e.g., paddle 320 a) rotates, the firstdistance 330 reaches a maximum of about 1 inch. In one embodiment, thefirst distance 330 reaches a maximum of about 0.5 inch. In oneembodiment, the ratio of the first distance to the diameter of theproduct conduit (e.g., former) is a maximum of about 0.041. In oneembodiment, the ratio of the first distance to the diameter of theproduct conduit (e.g., former) is a maximum of about 0.143. In oneembodiment, the settler 308 is positioned so that, as the paddle (e.g.,paddle 320 a) rotates, the paddle will first contact the package film202 at a first point that is a second distance 332 below the productconduit 204. In some embodiments the second distance 332 is about 0.5inch to about 3.6 inches.

In one embodiment, the settler 308 is used with a form, fill and sealmachine that further comprises a source of pressurized gas (e.g.,compressor 224). In one embodiment, the source of pressurized gas 224comprises a nozzle 226 to direct the pressurized gas into the packagefilm 202. In one embodiment, the source of pressurized gas 224 isselected from the group consisting of a fan, a blower, or a centrifugalcompressor.

In one embodiment, pressurized gas is used to provide pressure on theinside of the package film 202. This can be useful when a package filmis not resilient enough on its own to move out of a deformed position(e.g., the deformed position illustrated in FIG. 3B) that results whenthe settler 308 impacts the package film 202. When pressurized gas isused and the impact face 406 of the film 202 is not in a deformedposition caused by the settler 308, the position of the impact face willbe different from the position of the impact face when the inside of thepackage film is not under pressure. In other words, rather than being ina first position as illustrated in FIG. 3A, the impact face 406 will bein a second position that can be similar to the position illustrated inFIG. 3A, but can also be further from a central axis 334 of a package(e.g., package 404 b).

As another example, in one embodiment, the package film 202 comprises animpact face 406 that is adjacent to the product settler 308. When thepackage film 202 is filled with the pressurized gas and hangs under theforce of gravity, the impact face 406 defines a second position of theimpact face. This position can be substantially similar to the firstposition of the impact face 406 described with reference to FIG. 3A.However, when the impact face 406 is in the second position, the packagefilm 202 is filled with a pressurized gas, and the pressure from the gascan push the surface of the package film, including the impact face 406,outward. Accordingly, the second position of the impact face 406 can belocated further away from a central axis 334 of a package (e.g., thesecond package 404 b) than the first position of the impact face. In oneembodiment, the settler 308 is positioned so that as the paddle (e.g.,paddle 320 a) rotates, a first tip 328 of the paddle will reach past thesecond position of the impact face 406 by a third distance. The thirddistance can be substantially the same as the first distance 330 shownin FIG. 3B. However, the third distance can also be greater than thefirst distance 330 when the second position of the impact face 406 isfurther from the central axis 334 than the first position of the impactface 406. In one embodiment, as the paddle (e.g., paddle 320 a) rotates,the third distance reaches a maximum of about 0.5 to 4, 1 to 3, 1 to 2,2 to 3 or about 2.5 inches. In one embodiment, the ratio of the thirddistance to the diameter of the product conduit (e.g., former) is amaximum of about 0.041. In one embodiment, the ratio of the thirddistance to the diameter of the product conduit (e.g., former) is amaximum of about 0.208.

For example, in one embodiment, the distance from the first tip 328 of apaddle 320 a to the axle 602 of a paddle wheel 326 is about 2.5 inchesand the axle of the paddle wheel is positioned about 0.5 inches from theimpact face 406 of a package 202. Accordingly, when the paddle 320 arotates, the first tip 328 reaches past the original position of theimpact face 406 by about 2.0 inches and the third distance is about 2.0inches.

In one embodiment of an apparatus according to the invention, a packagefilm 202 is wrapped around the product conduit 204. The apparatus cancomprise a plurality of conveyors 214 a,b positioned to convey thepackage film 202 along the product conduit 204 at substantially a singlespeed along a perimeter 218 of the packaging film. The product conduit204 is selected, for example, from the group consisting of a tube, achute, a duct, and a pipe.

In one embodiment illustrated in FIG. 5A the apparatus is a form, filland seal machine that comprises a positional sensor 614 to determine theposition of the paddle wheel 326. For example, in one embodiment, themachine comprises a product settler 308 and the product settlercomprises the positional sensor 614.

The positional sensor 614 can be, for example, a camera orelectromagnetic device. The positional sensor 614 can also be aproximity switch. For example, in one embodiment, the positional sensor614 senses the presence or absence of a sensor target 622 (e.g., amagnet) within a given range of the positional sensor. In anotherembodiment, the positional sensor 614 senses a distance from thepositional sensor 614 to the sensor target 622. For example, the sensortarget 622 can move (e.g. rotate) with the paddle wheel 326 so that theposition of the sensor target indicates the position of the paddlewheel. In another example, the position of a portion 624 (e.g., a magnetor discontinuity) of the sensor target indicates the position of thepaddle wheel 326.

In one embodiment, the positional sensor 614 is used to position thepaddle wheel 326 or a paddle (e.g., paddle 320 a). For example, when thepaddle wheel 326 is stopped, the paddle wheel can be stopped outside thepath of a package film 202. This can be desirable because if the paddlewheel 326 is stopped in the path of the package film 202, the paddlewheel 326 will increase the resistance that must be overcome to conveythe package film.

One embodiment of the invention will now be described with reference toFIGS. 6A-6B. A settler 308 comprises a paddle wheel 326. The paddlewheel 326 comprises a plurality of paddles (e.g., paddles 320 a,b). Thepaddles 320 a,b rotate around an axle 602. As shown in FIGS. 6A and 6Bthe paddles 320 a,b are fixed to the axle 602, although in otherembodiments the paddles 320 a,b are not fixed to the axle directly, butare instead fixed to another component that rotates around the axle.

As shown, for example, in FIG. 6C, the product settler 308 comprises afirst adjustable mount 604 to adjust the position of the product settlerin a first direction 606. The product settler 308 comprises a secondadjustable mount 608 to adjust the position of the product settler in asecond direction 610. As shown in FIG. 6B, the product settler 308 alsocomprises a third adjustable mount 512 to adjust the position of theproduct settler in a third direction 620. As can be seen, the threedirections 606, 610 and 620 are represented by vectors having the sameorigin, and the three vectors can be mutually perpendicular.Additionally or alternatively, each vector can have the same origin andbe non-parallel to the other two vectors. With reference to FIG. 10, asingle mount (e.g., mount 604/512) can effectively provide the functionof a plurality of adjustable amounts, if the mount (e.g., mount 604/512)enables the adjustment of the position of the product settler 308 in aplurality of directions (e.g., directions 606, 620).

With reference to FIG. 6B, the product settler 308 comprises acontroller 612 to set the number of impacts against the package filmthat the product settler causes. For example, the number of impacts perminute can be calculated by multiplying the number of paddle wheels bythe number of rotations or revolutions per minute that the paddle wheel326 performs. Although, if another object is used to impact the packagefilm, for example, a rod that oscillates into and out of contact withthe package film, the number of impacts per minute will need to becalculated differently. For example, one end of the rod can be fixed toa rotating sphere and the other end of the rod can follow an orbitalpattern into or out of contact with the package. As another example, therod can move linearly back and forth between two positions, for example,a first position in contact with the package film and a second positionremote from the package film. Regardless of the mechanism used to causean impact, in some embodiments the number of impacts against a packageor package material is greater than about 180 impacts per minute, about240 impacts per minute, about 300 impacts per minute, about 360 impactsper minute, about 420 impacts per minute, about 480 impacts per minute,about 540 impacts per minute, about 600 impacts per minute, or about 660impacts per minute. In some embodiments, the number of impacts perminute is about 300 impacts per minute to about 900 impacts per minute.In some embodiments, the number of impacts is about 540 impacts perminute to about 720 impacts per minute. In some embodiments, the numberof impacts is about 600 impacts per minute to about 660 impacts perminute.

Turning back to FIG. 6B, the illustrated product settler also comprisesa positional sensor 614 (e.g., proximity switch) to determine theposition of the paddle (e.g., paddle 320 a). In one embodiment, thecontroller 612 uses information from the positional sensor 614 toinstruct the actuator 616 to stop the paddle (e.g., paddle 320 a) whenthe paddle is in a desired position.

As can be seen in FIG. 6C, the product settler 308 comprises a motor 616with sufficiently low torque that if the motor turns off while thepaddle (e.g., paddle 320 a) is contacting the package film 202, as thepackage film is conveyed, the package film will push the paddle out ofthe path of the package film. Although the benefits of using a lowtorque motor have been described with respect to turning off the motor,the similar benefits will be realized if the product settler fails orloses power. In one embodiment, the settler is powered by a small AC/DCdrive motor that will rotate the paddle wheel. For example, in oneembodiment the actuator (e.g., motor) for the inventive settler requiresa maximum of 96 Watts to settle product.

As shown in FIGS. 6A-6C and FIGS. 5A-5C, the product settler 308comprises a frame 618 that fixes the position of the product settler 308in relation to the path of the package film 202. For example, as shownin FIG. 5A, the product settler 308 is adjacent to a package 404 b. Thepackage 404 b extends on both sides of a center plane 531 that isoriented parallel to a central axis (e.g., central axis 334 in FIGS. 2and 3A-3C) of the package 404 b. In some embodiments the frame 618comprises adjustable mounts (e.g., the first adjustable mount 604, thesecond adjustable mount 608, and/or the third adjustable mount 512) tofacilitate changing the position of the product settler 308 relative tothe form, fill and seal machine 206.

For example, in one embodiment, the adjustable mounts 604, 608, 512 canbe used to move adjust the position of the product settler 308 in one,two, or three directions. For example, the first adjustable mount 604,second adjustable mount 608, and third adjustable mount 512 can be usedto move or adjust the position of the product settler 308 in a firstdirection 606, second direction 610, or third direction 620,respectively. In one embodiment, the adjustable mounts 604, 608, 512 canbe used to move or adjust the position of the product settler 308 in aplurality of mutually perpendicular directions (e.g., two or three). Inother embodiments, the frame 618 does not comprise the adjustable mounts604, 608, 512 and the frame is positioned in a desired location when itis installed on a form, fill and seal machine 206.

As shown in FIGS. 5A-5C, the first adjustable mount 604 comprises afirst mechanism (e.g., bolts 528 a,b) to fix the product settler 308 ina desired vertical position relative to the form, fill, and seal machine206. The second adjustable mount 608 comprises a second mechanism (e.g.,bolt 530) to fix the product settler 308 at a desired proximity to theform, fill, and seal machine 206. The third adjustable mount 512comprises a third mechanism (e.g., bolts 532 a,b) to fix the productsettler 308 in a desired horizontal position relative to the form, fill,and seal machine 206.

One embodiment of the invention will now be described with reference toFIGS. 5A-5C and FIG. 8. As shown, the product settler 308 is modular.For example, besides connecting the product settler 308 to a form, fill,and seal machine, no assembly is required for the product settler.Accordingly, in one embodiment, the product settler 308 is operableafter being electronically connected to a power source and placed in adesired position relative to the form, fill and seal machine 206. In oneembodiment, this is accomplished by mounting a module in the form of aproduct settler 308 on the form, fill and seal machine 206 using amachine mount 502. For example, the machine mount 502 can connect theframe 618 of the product settler 308 (see, e.g., FIGS. 5A-5C) to theframe 702 a,b of the form, fill and seal machine 206 (see, e.g., FIG.7). In one embodiment, the machine mount 502 is fixed to controller 612using a mechanism 534 such as screws or bolts (see, e.g., FIGS. 5A-5C).The same mechanism 534 or an additional mechanism can also be used tofix the machine mount 502 to the form, fill and seal machine 206.

In one embodiment shown in FIGS. 5A-5C, a modular product settler 308 islinked to a form, fill, and seal machine through a line of communication(e.g., one of a plurality of lines of communication 504 a,b). The lineof communication can be electronic, pneumatic, or some other manner ofconveying power and/or information. For example, a line of communication(e.g., 504 a,b) can provide an electronic line of communication betweenthe product settler 308 and the form, fill and seal machine 206. Inturn, the form, fill and seal machine 206 can provide a power source 508for the product settler 308. Although, the product settler 308 can alsobe connected to a power source 508 (e.g., power outlet or battery) thatis separate from the form, fill and seal machine 206. Similarly, a lineof communication (e.g., 504 a,b) can connect the product settler 308 toa controller 612 for the product settler. In turn, the controller 612can be used to control the position of the paddle wheel 326 inconjunction with a positional sensor 614. Furthermore, the controller612 can be used to control the angular velocity or rotational speed ofthe paddle wheel 326. In some embodiments, a plug 506 is provided tofacilitate connecting and disconnecting a line of communication betweenthe product settler 308 and a component (e.g. the controller 612) or theform, fill and seal machine 206. In some embodiments, the line ofcommunication between the product settler 308 and the form, fill andseal machine 206 goes through the controller 612. In some embodiments,the controller 612 for the product settler 308 is in communication withthe form, fill and seal machine 206 through an auxiliary port 510 of theform, fill and seal machine 206. Accordingly, in some embodiments a lineof communication (e.g., 504 a,b) exists between the form, fill and sealmachine 206 and the product settler 308 so that a control system of theform, fill and seal machine 206 can be used to control the controller612 of the product settler 308, and thereby control the product settler308.

The product settler 308, shown in FIGS. 5A-5C also comprises a timingbelt 514 which is used to actuate the product settler 308. The timingbelt 514 is wrapped around a rotor 516 and an axle 602. When that therotor 516 is rotated by motor 616, it causes the timing belt 514 totravel around the axle 602. This, in turn, causes the axle 602 torotate, which rotates the paddle wheel 326.

In the embodiment shown in FIGS. 5A-5C, the product settler 308comprises a timing belt guard 518. The timing belt guard protects thetiming belt from being caught on an object, for example, product 302 orfilm 202. Similarly, as shown in FIGS. 6A-6C, the frame 618 of theproduct settler 308 can comprise a paddle guard that protects the paddle(e.g., on one side or a plurality of sides) from being obstructed byobjects other than the package film 202.

As can be seen in FIG. 7, the product settler 308 is unobtrusive. Theproduct settler is fairly small, lightweight, and located to one side ofthe seal jaw carriage 704 a,b so it does not obstruct access to thecarriage for repair or maintenance. For example, as shown in FIGS.5B-5C, one embodiment of the product settler has a length 522 of about24 inches, a width 524 of about 16, and a height 526 of about 8 inches.In some embodiments, the product settler has a length 522 of about 6 toabout 30 inches, a width 524 of about 6 to about 30 inches, and a height526 of about 4 to about 12 inches. In one embodiment, the productsettler, excluding the machine mount 502 and third adjustable mount 512,weighs a maximum of about 12 lbs. In comparison, conventional productsettlers, excluding mounting plates, typically weight about 50 lbs.

Additionally, the product settler can be easily installed oruninstalled. For example, with reference to the embodiment shown inFIGS. 5A-5C, a portion of the product settler can be uninstalled byremoving a plug 506 and detaching the portion from the machine mount502, which can be left attached to a form, fill, and seal machine 206.Alternatively, the machine mount 502 can be detached from the form, filland seal machine 206. This can be done without (or in addition to)removing the plug 506 and detaching a portion of the product settler 308from the machine mount 502.

Although the inventive product settler has been described by referenceto use of a package made from film. The package material can be madefrom a film or some other form of material. For example, the inventivesettler can be used with packages made from package materials of varyingthicknesses. Furthermore, the package material can be, for example,paper, metal, metal oxides, polymer, or some combination thereof.

EXAMPLES

Illustrative examples of the inventive settler and experiments involvingthe inventive settler will now be described.

Example 1

An experiment was conducted to measure certain benefits of using theinventive product settler 308 described herein. A continuous motionvertical form, fill and seal machine 206 was fitted with the inventivesettler 308. Then, the machine 206 was used to produce 13.0 oz packages202 containing TOSTITOS® Restaurant Style Tortilla Chips. The machine206 ran at a speed of about 26 packages per minute. The packages 202were produced on a product conduit 204 (e.g., former) with a circularcross-section. The cross-section of the product conduit 204 had adiameter of about 10.5 inches, and accordingly the packages 202 had adiameter of about 10.5 inches while wrapped around the product conduit.The packages 202 had a length of about 15.75″ from the tip of a firstend seal 212 a to the opposite tip of a second end seal 212 b. Each endseal 212 a,b was approximately ⅜ inches long providing a total usablepackage length of about 15 inches. In other words, the length of thepackage 202 that could be filled with product was approximately 15inches.

A first set of five packages 202 were produced on a machine 206 withoutusing the inventive settler 308. The average package head space wasabout 1.3 inches and the average unsettled height 314 of the product wasabout 13.7 inches. A second set of five packages 202 were produced onthe machine 206 with the inventive settler 308 activated. Using this setup, the average package head space was about 2.9 inches and the averagesettled height 312 of the product was about 12.1 inches. As can be seen,the inventive settler resulted in an average settling of about 1.6inches, which is a settling fraction of at least about 0.116 relative tothe unsettled height 314 of the product.

Additionally, the inventive settler reduced the average length of filmrequired to package each unit of product by about 1.6 inches. Forexample, rather than increasing the head space in a package, the productsettler could also have been used to maintain a given head space whiledecreasing the length of film required for the package. In this example,the length of film required to package each unsettled unit of productwas 15.75 inches. Since the product settler resulted in settling ofabout 1.6 inches, the product settler could have reduced the length offilm required by 1.6 inches. This is a film reduction fraction of atleast 0.101 relative to the length of film required if no settler isused.

Breakage of product occurring with and without the inventive settleractivated was substantially the same. The use of the inventive settlerdid not result in any statistically significant increase in the ratio ofbroken product to non-broken product in a package. In other words, anyincrease in breakage was within the margin of error for the experiment.

Table 1

Table 1 provides speeds in packages per minute at which an illustrativeform, fill and seal machine can produce packages with a clamp on. Allinformation in the table corresponds to a seal time of 70 milliseconds.In other words, the seal jaws press against the film for approximately70 milliseconds to form package end seals. The table shows how packageproduction speeds vary with bag length. As can be seen, increasedpackage lengths result in lower package production speeds. This isbecause, given a fixed speed for conveying packages, longer packagesrequire more time to be convey.

TABLE 1 Package length Production Speed (inches) (packages/minute) 27.9919 27.5 19 27 19 26.5 19 26 20 25.5 20 25 21 24.5 21 24 22 23.5 22 23 2322.5 23 22 24 21.5 24 21 25 20.5 25 20 26 19.5 27 19 27 18.5 28 18 2917.5 30 17 31 16.5 32 16 33 15.5 34 15 35

Example 2

A method for settling a product 302 in a package 404 made on a form,fill and seal machine 206 will now be described with reference, forexample, to FIG. 2. It should be understood that the elements describedin this method are not mutually exclusive with any other illustrativemethod or apparatus described herein. Rather, the elements described canbe added to or substituted for elements described in any otherillustrative method or apparatus herein.

Turning to FIG. 2, in one illustrative embodiment, the method comprisesthe steps:

-   -   a. providing a package material (e.g., package film 202) on a        product conduit 204 of a form, fill and seal machine 206;    -   c. forming a first end seal 212 a on the package material 202 to        form a partially formed package (e.g., second package 404 b in        FIG. 2);    -   d. filling the partially formed package 404 b with the product        302; and    -   e. settling the product 302 in the partially formed package 404        b while continuously conveying the package material 202 along        the product conduit 204.

It is contemplated that filling the partially formed package 404 b withthe product 302 can comprise filling the partially formed package 404 bwith a desired amount of product 302 or with an amount of product thatprovides the package 404 with a desired amount of headspace.Additionally, it is contemplated that the first end seal 212 a can beformed approximately perpendicularly to a longitudinal seal 402 or thefirst end seal 212 a can be formed within 30, 25, 20, 15, 10, or 5degrees of perpendicular to the longitudinal seal 402.

In some embodiments, the method comprises at least one step selectedfrom the group consisting of:

-   -   b. sealing the package material 202 to form a longitudinal seal        402;    -   f. forming a second end seal 212 b on the partially formed        package 404 b to form a package 404 from the partially formed        package 404 b; and    -   a combination thereof.

In some embodiments, the settling step comprises the steps:

-   -   (i) pressurizing an interior of the partially formed package 404        b to provide resistance; and    -   (ii) intermittently contacting the partially formed package 404        b to move the partially formed package 404 b, thereby moving the        product 302.

In some embodiments, the settling step comprises the steps:

-   -   (i) rotating a paddle wheel 326 comprising a paddle 320 a (or        plurality of paddles 320 a,b); and    -   (ii) intermittently rotating the paddle 320 a into contact with        the partially formed package 404 b, thereby moving the product        302 while the product 302 is inside the partially formed package        404 b.

In some embodiments, an actuator 616 oscillates or rotates the paddle320 a and stops the paddle 320 a in a desired position. This can beuseful, for example, to avoid the paddle stopping in contact with apackage material 202 or in the path of a package material, which couldamong other things, damage the packaging material or damage the actuator616 if the film pushes the paddle, depending on the type of actuatorused.

In some embodiments, the actuator 616 is characterized by a featureselected from the following group of features:

-   -   (i) the actuator 616 is a motor 616;    -   (ii) the actuator 616 is a stepper motor 616;    -   (iii) the actuator 616 is programmable to change (e.g., increase        or decrease) an oscillatory or rotational speed of the paddle        320 a at a desired rate;    -   (iv) the actuator 616 is programmable to control acceleration        (e.g., increasing or decreasing rotational speed) of the paddle        wheel 326;    -   (v) the actuator 616 is programmable to select the position of        the paddle 320 a when the paddle 320 a stops; and    -   (vi) a combination thereof.

In some embodiments, the method comprises a step selected from the groupconsisting of:

-   -   (i) using the actuator 616 to change (e.g., increase or        decrease) an oscillatory or rotational speed of the paddle 320 a        at a first desired rate by changing an oscillatory or rotational        speed of a component of the actuator 616 (e.g., rotor 516, drive        shaft, piston, etc.), wherein the component of the actuator is        linked to the paddle, and optionally using the actuator 616 to        change the oscillatory or rotational speed of the paddle 320 a        at a second desired rate by changing the oscillatory or        rotational speed of the component of the actuator 616;    -   (ii) using the actuator 616 to control acceleration (e.g.,        increasing or decreasing rotational or oscillatory speed) of the        paddle 320 a, the plurality of paddles 320 a,b, the paddle wheel        326, or a combination thereof;    -   (iii) using the actuator 616 to stop the paddle 320 a (or each        of the plurality of paddles 320 a,b) in a desired position        (e.g., out of a path of the package material 202 or out of        contact with the package material 202); and    -   (iv) a combination thereof.

Several illustrative features of a product settler 308 will now bedescribed with reference to FIG. 8, which illustrates the use of theproduct settler through several scenes that progress in time from leftto right. Starting with the leftmost scene, an impact face 406 of apackage material 202 is illustrated in a first position 804. Asillustrated, the package material 202 hangs under the force of gravityand any force of internal pressure (e.g., from a source of pressurizedgas (e.g., compressor 224). Additionally, the product settler 308 isinactive and out of contact with the package material 202.

Next, as time progresses, the product settler 308 has moved into contactwith the impact face 406 to displace the package material 202 by a firstdistance 330 in the horizontal direction. Accordingly, the impact face406 of the package material 202 is in a second position 806.

Then, as time progresses, the product settler 308 has moved out ofcontact with the package material 202. However, a flow 812 of aircreated by the movement of the product settler 308 results in a force onthe package material 202 that keeps the impact face 406 from returningto the first position 804. Rather, the impact face 406 of the packagematerial 202 has moved to a third position 808. As can be seen, ahorizontal displacement of the impact face 406 from the second position806 to the third position 808 provides an amplitude 802 of vibration forthe impact face 406 of the package material 202. As a result of the flow812 of air created by the movement of the product settler 308, theamplitude 802 of vibration is less than it could be if the impact face406 returned to the first position 804.

As time continues to progress, the product settler 308 has moved againinto contact with the impact face 406 of the package material 202.Accordingly, the impact face 406 of the package material 202 is in afourth position 810, which is similar to the second position 806,although it could be different if the paddles 320 a,b of the productsettler 308 were to have different lengths. Also, while not illustrated,the cycling of the impact face 406 between a position similar to thethird position 808 and a position similar to the fourth position 810 cancontinue until the settling movement of the product settler 308 isstopped.

As explained with respect to the third position 808, as a result of theflow 812 of air created by the movement of the product settler 308, theamplitude 802 of vibration can be less than an amplitude 802 ofvibration that would occur if the impact face 406 returned to the firstposition 804, or at least a position closer to the first position 804.Accordingly, in some embodiments, it is desirable to configure theproduct settler 308 so that it produces no more than a limited,specified flow 812 of air. This can be accomplished, for example, byincluding at least one aperture 536 in the product settler 308. In someembodiments, the at least one aperture is positioned in a rotatingpaddle 320 a or plurality of paddles 320 a,b that make up a paddle wheel326. As a skilled person would understand after reading this disclosure,by reducing the flow 812 of air created by the movement of the productsettler 308, the impact face 406 of the package material 202 can cyclebetween a position similar to the first position 806 and a positionsimilar to the second position 806 rather than a position similar to thethird position 808 and the fourth position 810. Advantageously, thisresults in a relatively larger amplitude 802 of vibration of the impactface 406 and can help to better settle product 302.

With reference again to FIG. 8, in some embodiments, the settling stepof a method described herein comprises using a product settler 308 toprovide the package material 202 with an amplitude 802 of vibrationequal to at least 3, 2.5, 2, 1, 0.9, 0.8, 0.7, 0.6, 0.5, 0.4, 0.3, 0.2,or 0.1 inches, no more than 3, 2.5, 2, 1, 0.9, 0.8, 0.7, 0.6, 0.5, 0.4,0.3, 0.2, or 0.1 inches, or a combination thereof. As illustrations ofthe amplitude 802 of vibration, in some embodiments, the amplitude 802of vibration can be equal to the first distance 330 illustrated anddescribed, for example, with reference to FIG. 3B. In some embodiments,the amplitude 802 of vibration can be greater than the first distance330, for example, if the package material 202 is pushed beyond the firsttip 328 of the paddle and/or the package material moves beyond aposition of the impact face 406 when the impact face 406 is hangingunder gravity and any internal pressure. Additionally, as illustrated inFIG. 8, in some embodiments the amplitude 802 of vibration can be lessthan the first distance 330, for example, if the flow 812 of air fromthe paddle prevents the impact face 406 from returning to a position 804of the impact face 406 when the impact face 406 is hanging under gravityand any internal pressure.

In some embodiments, a method described herein is characterized by oneor more of the following features. First, with reference, for example,to FIG. 6A, in some embodiments, the paddle 320 a (or each of aplurality of paddles 320 a,b) comprises at least one aperture 536.

Second, with reference to FIGS. 3A-3C, in some embodiments, a paddle 320a contacts the package 404 once per rotation of the paddle 320 a.

Third, with reference to FIG. 8, in some embodiments the packagematerial 202 is pushed by a flow 812 of air created by the rotation ofthe paddle 320 a, for example, rather than contact with the paddle 320a. However, in some embodiments, it can be useful to limit the force ofthe flow 812 of air on the package material 202, for example, to helpmaintain a desired amplitude of vibration. Accordingly, in someembodiments, the flow 812 of air pushes the package material by no morethan and/or at least 1, 0.9, 0.8, 0.7, 0.6, 0.5, 0.4, 0.3, 0.2 or 0.1inches from a hanging reference position. With reference to FIG. 8, insome embodiments, the hanging reference position is a position of thepackage material 202 when the package material 202 hangs under the forceof gravity and any force of internal pressure (e.g., from a source ofpressurized gas (e.g., compressor 224) and when the product settler 308is inactive and out of contact with the package material 202. An exampleof a hanging reference position is illustrated by first position 804 inFIG. 8.

Fourth, with reference again to FIG. 8, in some embodiments, afterimpact by a paddle 320 a (or each of a plurality of paddles 320 a,b) thepackage material 202 returns to a hanging reference position asdescribed herein.

Several illustrative features of a product settler 308 will now bedescribed with reference to FIG. 9, which illustrates a paddle 320 aimpacting a package material 202. As will be better understood withreference to FIG. 9, it can be desirable for a paddle 320 a to berelatively rigid, depending on the application. In some embodiments, thepaddle 320 a does not bend by more than a specified bend tolerance 902during use, for example, as a result of contact with the packagematerial 202. As illustrated in FIG. 9, the specified bend tolerance 902is an angle measured in a plane that is perpendicular to the axis ofrotation 626 of the paddle wheel 326, for example, in the plane of FIG.9. In some embodiments, the specified bend tolerance is no more than 30,20, 15, 10, 5, 4, 3, 2, or 1 degrees. As illustrated in FIG. 9, thespecified bend tolerance 902 is measured for a leading surface 912 ofthe paddle 320 a. Additionally, the specified bend tolerance 902 ismeasured from a proximal reference line 904 to a distal reference line906, wherein the proximal reference line 904 is parallel to a proximalend 908 of the paddle 320 a and the distal reference line 906 isparallel to a distal end 910 of the paddle 320 a. With reference to FIG.9, the proximal end 908 is the end closer to an axis of rotation 626 ofthe paddle wheel 326. The distal end 910 is the end further from an axisof rotation 626 of the paddle wheel 326.

Example 3

An improved continuous motion form, fill and seal machine 206, will nowbe described with reference, for example, to FIG. 2. It should beunderstood that the elements described in this apparatus are notmutually exclusive with any other illustrative apparatus or methoddescribed herein. Rather, the elements described can be added to orsubstituted for elements described in any other illustrative method orapparatus herein.

As illustrated in FIG. 2, the improved continuous motion form, fill andseal machine 206 comprises a product conduit 204, a conveyor (e.g.,conveyor 214 a,b), and seal jaws (e.g., a cooperative pair of seal jaws216 a-d). The conveyor 214 a,b is positioned to convey a packagematerial (e.g., package film 202) that is wrapped around the productconduit 204. For example, as illustrated, the conveyor 214 a,b moves thepackage material 202 along the product conduit 204.

With reference again to FIG. 2, the seal jaws 216 a-d are positionedadjacent to opposite portions of the package material 202 to form afirst end seal 212 a on the package material 202, thereby forming apartially formed package (e.g., second package 404 b in FIG. 2).

The product conduit 204 of the machine 206 is positioned so that aproduct 302 passing through the product conduit 204 will enter thepartially formed package 404 b after exiting the product conduit 204.Additionally, the product conduit 204 is positioned above the seal jaws216 a-d.

With reference to FIG. 2, the improvement to the continuous motion form,fill and seal machine comprises a product settler 308. As illustrated,the product settler 308 comprises a first object (e.g., paddle 320 a,b)positioned to cause an impact against the package material 202. Theimpact agitates the package material 202 and settles the product 302from an unsettled height 314 to a settled height 312 while the machine206 continuously conveys the package material 202 along the productconduit 204.

With further reference to FIG. 2, in some embodiments, the machine 206comprises a source of pressurized gas (e.g., compressor 224), andconduit (e.g., a nozzle 226) to direct the pressurized gas into thepackage material 202.

With reference to FIG. 3B, in some embodiments, the impact occurs on oneand only one face (e.g., impact face 406) of the partially formedpackage.

With reference to FIG. 3B and FIG. 3C, in some embodiments, the impactagainst the package material 202 occurs below the product conduit 204and above the unsettled height 314.

With reference to FIG. 3B, FIG. 6c , FIG. 6d , FIG. 10 and FIG. 11, insome embodiments, the product settler 308 comprises a motor 616 withsufficiently low torque so that if the motor 616 stops (e.g., turns off)while the first object is in contact with the package material 202, asthe package material 202 is conveyed, the package material 202 will pushthe first object out of a path of the package material 202.

With reference to FIG. 3A, FIG. 3B and FIG. 3C, in some embodiments thefirst object positioned to cause an impact against the package material202 is a rotatable paddle wheel 326. As illustrated, the paddle wheel326 comprises a paddle 320 a, and the paddle 320 a is positioned sothat, as the paddle wheel 326 rotates, the paddle 320 a causes agitationof the package material 202 and thereby settles the product 302.

With reference to FIG. 3A, FIG. 3B, FIG. 3C, and FIG. 8, in someembodiments, the package material 202 comprises an impact face 406, andthe impact face 406 is adjacent to the product settler 308. Asillustrated, when the impact face 406 of the package material 202 hangsunder a force of gravity, the impact face 406 defines a first position804. As illustrated, for example, in FIG. 8, the product settler 308 ispositioned so that as the paddle wheel 326 rotates, a first tip 328 ofthe paddle 320 a will reach past (e.g., horizontally past) the firstposition 804 by a first distance 330. In some embodiments, the firstdistance 330 reaches at least and/or no more than about 0.25, 0.5, 1,1.5, 2, 2.5 or 3 inches while the paddle wheel 326 rotates.

For purposes of illustration, several features of a product settler 308will now be described with reference to FIG. 10 and FIG. 11. As askilled person would understand upon reading this disclosure, many ofthe elements of FIGS. 10 and 11 have already been described with respectto FIG. 6B and FIG. 6C, respectively. Accordingly, these elements arenot be addressed again. However, for purposes of comparison, it isevident that FIG. 10 and FIG. 11 illustrate a motor 616 comprising arotor 516, which also serves as an axle 602 for a paddle wheel 326. Ascan be seen, the rotor 516 and the axle 602 have concentric axes ofrotation. In contrast, FIG. 6B and FIG. 6C illustrate an embodiment inwhich a rotor 516 (not illustrated) for the motor 616 and an axle 602for the paddle wheel 326 have different axes of rotation.

FIG. 12 illustrates how a product settler with concentric axes (e.g.,axis 1302 and axis 626) of rotation for a rotor 516 and a paddle wheel326 can be used to settle product in conjunction with a vertical, form,fill, and seal machine. Most of the components of FIG. 12 have alreadybeen described, for example, with reference to FIG. 7, and need not befurther discussed.

FIG. 13 illustrates how it can be advantageous to provide a productsettler or its components with a desirable size and geometry, forexample, to facilitate installation, maintenance or proper operation. Asan illustration, in some embodiment it can be advantageous if theproduct settler, its motor, or its paddle wheel fit within a specifiedvolume or a specified cross-sectional area. With reference to FIG. 13,if the rotor 516 for a motor 616 and the axis of rotation paddle wheel326 have concentric axes of rotation, and both the motor 616 and paddlewheel 326 are adjacent to a package material 202, then it can be usefulfor the paddle wheel 326 to have a cross-sectional radius (correspondingto radius 1310 of imaginary cylinder 1304 as illustrated in FIG. 13)that is larger than the cross-sectional radius (corresponding to radius516 of imaginary cylinder 1306 in FIG. 13) of the motor 616. Forexample, this will enable the paddle wheel 326 to reach the packagematerial 202. Alternatively, such a configuration may be lessadvantageous if only the paddle wheel 326 is adjacent to the packagematerial 202 and the motor 616 is not in a position to block the packagematerial 202 from coming into contact with the paddle wheel 326.

With reference again to FIG. 10, FIG. 11, FIG. 12 and FIG. 13, in someembodiments, the product settler 308 comprises a motor 616, and themotor comprises a rotor 516. As illustrated, the motor 616 causes therotor 516 to rotate. As shown, for example, in FIG. 13, the rotor 516can also be an axle 602 for the paddle wheel 326, and/or the axis 1302of rotation for the rotor 516 and the axis 626 of rotation for thepaddle wheel 326 can be concentric.

As a skilled person would understand after reading this disclosure, someembodiments described herein include one or more of the followingfeatures. First, with reference to FIG. 13, in some embodiments, therotor 516 is straight from the motor 616 and along the portion of therotor 516 that acts as the axle 602 for the paddle wheel 326.

Second, in some embodiments, no force transfer components (e.g., gears,belt, etc.) apart from the rotor 516 are used between the motor 616 andthe paddle wheel 326.

Third, in some embodiments, the product settler 308 occupies less spacethan a reference product settler 308 that comprises the force transfercomponents.

Fourth, with reference to FIG. 10, in some embodiments, the motor 616,the rotor 516, and the paddle wheel 326 fit within a reference cylinder1002. For example, the reference cylinder can circumscribe thesecomponents. As illustrated, the reference cylinder has a referencecylinder radius 1004 of no more than and/or at least 8, 7, 6, 5, 4, 3,2, 1.5, 1 or 0.5 inches. The reference cylinder has a reference cylinderheight 1006 of no more than and/or at least 24, 20, 18, 16, 15, 14, 13,12, 11, 10, 9, 8, 7, 6, 5, 4, 3, or 2 inches. As a skilled person wouldunderstand upon reading this disclosure, many of the elements of FIGS.10 and 11 have already been described with respect to FIG. 6B and FIG.6C, respectively. Accordingly, these elements are not be addressedagain. However, for purposes of comparison, it is evident that FIG. 10and FIG. 11 illustrate a motor 616 comprising a rotor 516, which alsoserves as an axle 602 for a paddle wheel 326. As can be seen, the rotor516 and the axle 602 have concentric axes of rotation. In contrast, FIG.6B and FIG. 6C illustrate an embodiment in which a rotor 516 (notillustrated) for the motor 616 and an axle 602 for the paddle wheel 326have different axes of rotation.

Fifth, with reference to FIG. 13, in some embodiments, an axis 1302 ofrotation for the rotor 516 of the motor 616 and an axis 626 of rotationfor the paddle wheel 326 are concentric. Additionally, as viewed from aside during use, the motor 616 can use more area than the paddle wheel326, the motor 616 can use less area than the paddle wheel 326, or boththe motor 616 and the paddle wheel 326 can use equal amounts of area. Inorder to characterize the amount of volume and/or area that the motor616 or the paddle wheel 326 uses, it is useful to define an imaginaryreference motor cylinder 1304 and an imaginary reference paddle wheelcylinder 1306, which can circumscribe the motor and paddle wheel,respectively. As illustrated in FIG. 13, the reference motor cylinder1304 has a central axis that is concentric with the axis 1302 ofrotation for the rotor 516, and the radius 1308 of the reference motorcylinder 1304 is the minimum radius that results in the reference motorcylinder 1304 being large enough to fully contain the motor (e.g., withno portion of the motor 616 protruding outside the reference motorcylinder 1304). Similarly, the reference paddle wheel cylinder 1306 hasa central axis that is concentric with the axis 1302 of rotation for therotor 516, and the radius 1310 of the reference paddle wheel cylinder1306 is the minimum radius that results in the reference paddle wheelcylinder 1306 being large enough to fully contain the paddle wheel 326(e.g., with no portion of the paddle wheel 326 protruding outside thereference paddle wheel cylinder 1306). With these definitions in mind,in some embodiments, the reference paddle wheel cylinder 1306 is atleast as large or larger than the reference motor cylinder 1304.Meanwhile, in some embodiments, the reference motor cylinder 1304 is atleast as large or larger than the reference paddle wheel cylinder 1306.

Sixth, in some embodiments, the motor, the rotor 516, the paddle wheel326 or a combination thereof fit within a volume equal to no more thanand/or at least 2, 1.9, 1.8, 1.7, 1.6, 1.5, 1.4, 1.3, 1.2, 1.1, 1.0,0.9, 0.8, 0.7, 0.6, 0.6, 0.4, 0.3, 0.2, 0.1, 0.5, 0.1, 0.05, 0.04 cubicfeet.

In some embodiments described herein, the motor 616 is characterized bya feature selected from the following group of features:

-   -   (i) the motor 616 is a stepper motor 616;    -   (ii) the motor 616 can be programmed to change (e.g., increase        or decrease) oscillatory or rotational speed of the first object        at a desired rate;    -   (iii) the motor 616 can be programmed to provide more control        over acceleration (e.g., increasing or decreasing rotational or        oscillatory speed) of the at least one object (e.g., paddle 320        a) or paddle wheel 326, to enable selecting the position of the        at least one object when it stops; and    -   (iv) a combination thereof.

For purposes of illustration, some features of a product settler 308will now be described with reference to FIG. 14, which depicts a productsettler comprising a paddle wheel 326. As illustrated, the paddle wheel326 comprises paddles 320 a-d and adjacent paddles are mutually orientedat a paddle spacing angle 1402 a-d. As can be seen, the paddle spacingangle 1402 a-d can vary from one pair of adjacent paddles to anotherpair of adjacent paddles.

FIG. 14 is useful to illustrate several features of some embodiments ofa product settler 308. For example, in some embodiments, a paddle wheel326 of the product settler 326 comprises a plurality of paddles 320 a-d(e.g., no more than and/or at least four, three, or two paddles).Nonetheless, it is also contemplated that in some embodiments, usingrelatively fewer paddles 320 is advantageous. For example, this can helpto facilitate the stopping of each paddle (as applicable) in a positionin which the paddle is not in contact with package material 202 and notin a path of the package material 202. In some cases, depending on thegeometry (e.g., arrangement, size, shape, etc.) of a plurality ofpaddles and/or a paddle wheel, it may be impossible or difficult toavoid stopping at least one of the plurality of paddles in a positionthat such that the at least one paddle is in contact with the packagematerial 202 or in a path of the package material 202. As a skilledperson would understand after reading this disclosure, it can bedesirable to avoid such a geometry for the plurality of paddles and/orpaddle wheel.

In some embodiments, the plurality of paddles 320 a-d are spaced arounda paddle wheel 326 to provide a paddle spacing angle 1402 a-d betweeneach set of two adjacent paddles in the plurality of paddles 320 a-d.Additionally, in some embodiments, the paddle spacing angle 1402 a-ddiffers from a common angle 1404 by no more than a specified tolerance1406 a,b. As used in this context, the common angle is defined to equal360 degrees divided by the number of paddles in the plurality of paddles320 a-d. With reference again to FIG. 14, in some embodiments, thespecified tolerance 1406 a,b has a magnitude of no more than 45, 30, 25,20, 15, 10, 5, 4, 3, 2 or 1 degrees.

In some embodiments, it can be useful for all of the paddle spacingangles to be approximately equal because, for example, this can help toprovide a vibration of a package material 202 that is relativelyconstant in terms of the time between impacts of a paddle 320 a (orother object) with the package material 202. Although, by way ofcomparison, it is also possible to create a vibration of a packagematerial 202 that is less constant in terms of the time between impactsof a paddle 320 a (or other object) with the package material, or interms of the amplitude of the vibration caused by subsequent impacts.For example, this can be accomplished using a paddle wheel 326 withdifferent paddle spacing angles, adjacent paddles with differentlengths, or adjacent paddles configured to displace the package material202 by different distances 330.

With reference, for example, to FIG. 6A and FIG. 8, in some embodiments,the first object (e.g., paddle 320 a,b) positioned to cause an impactagainst the package material comprises at least one aperture 536. Forexample, this can enable passage of air through the first object. Thiscan also help to avoid a fan-like effect in which the first objectcauses air to move into contact with the package material 202 and pushthe package material 202 away from the first object.

With reference again to FIG. 6A and FIG. 8, in some embodiments, thefirst object, paddle 320 a, or each of a plurality of paddles 320 a,b,comprises at least one aperture 536. With reference to FIG. 8, the atleast one aperture 536 can be configured to provide one or more of thefollowing characteristics. First, the aperture 536 can be configured toavoid creating a flow 812 of air that pushes the package material 202away from the paddle 320 a.

Second, the at least one aperture 536 can be configured to avoidcreating a flow 812 of air that pushes the package material 202sufficiently far away from the paddle 320 a during a rotation of thepaddle 320 a that the paddle 320 a does not contact the package material202 during the rotation.

Third, the at least one aperture 536 can be configured to avoid creatinga flow 812 of air that pushes the package material 202 by more than 1,0.9, 0.8, 0.7, 0.6, 0.5, 0.4, 0.3, 0.2 or 0.1 inches from a hangingreference position (e.g., a first position 804) in which the packagematerial 202 hangs under the force of gravity and any force of internalpressure (e.g., from a source of pressurized gas (e.g., compressor224)),

Fourth, the at least one aperture 536 can be configured to avoidcreating a flow 812 of air that prevents the package material 202 fromreturning to a hanging reference position (e.g., a first position 804)under the force of gravity and any force of internal pressure (e.g.,from a source of pressurized gas (e.g., compressor 224)),

Fifth, the at least one aperture 536 can be configured so that the atleast one aperture 536 (e.g., the aperture or the plurality ofapertures) has a total aperture surface area equal to at least and/or nomore than 30, 40, 50, 60, 70, 80, 85, 90, 95, 96, 97, 98, or 99% of asurface area of a leading surface 912 of the paddle 320 a.

In some embodiments, the first object (e.g., paddle 320 a) is rigid.

With reference to FIG. 9, in some embodiments, the first object does notbend by more than a specified bend tolerance 902 during use, forexample, as a result of contact with the package material 202. In someembodiments, the specified bend tolerance 902 is at least and/or no morethan 30, 20, 15, 10, 5, 4, 3, 2, or 1 degrees. As illustrated in FIG. 9,the specified bend tolerance 902 is measured from a proximal referenceline 904 to a distal reference line 906 and measured in a planeperpendicular to the axis 626 of rotation of the paddle wheel 326 (e.g.,plane of FIG. 9). Additionally, the proximal reference line 904 isparallel to a proximal end 908 of the first object and the distalreference line 906 is parallel to a distal end 910 of the first object.As used herein, the proximal end 908 of the first object is the endcloser to an axis 626 of rotation of the paddle wheel 326. Similarly,the distal end 910 of the first object is the end further from an axis626 of rotation of the paddle wheel 326.

In some embodiments, the first object (e.g., paddle 320 a,b) is madefrom a material selected from the group consisting of metal, alloy,steel, polymer, plastic, resin, rubber, and wood.

With reference, for example, to FIG. 3B and FIG. 8, in some embodiments,the length of a paddle 320 a from the axis 626 of rotation of the paddlewheel 326 to a distal end 910 of the paddle 320 a (as measured radiallyoutward from the axis of rotation of the paddle wheel) is long enough toenable to the paddle 320 a to reach the package material 202 and pastthe package material 202 by a first distance 330 equal to at leastand/or no more than 0.1, 0.2, 0.3, 0.4, 0.5, 0.75, 1, 1.5, 2 or 3inches. In some embodiments, the length of the paddle 320 a from theaxis 626 of rotation of the paddle wheel 326 to a distal end 910 of thepaddle 320 a (as measured radially outward from the axis of rotation ofthe paddle wheel) is equal to at least and/or no more than 0.1, 0.2,0.3, 0.4, 0.5, 0.75, 1, 1.5, 2, 3 or 4 inches.

Although the inventive settler is described herein as being installed onspecific embodiments of vertical form, fill, and seal machines, theinventive settler is not limited to being used with these machines.Rather, the inventive settler can be used, for example, with essentiallyany process where a product can be settled in a package. Although, theinventive settler is especially useful with processes where a film isbeing continuously advanced to form a package that is filled withproduct and then sealed. When used with such a process, the inventivesettler can settle product within the film while the film is beingcontinuously advanced. This is a substantial improvement overconventional settlers that require a film to pause intermittently forsettling.

Additionally, while the product settler has generally be described inthe form of a paddle wheel, some embodiments of the product settler foruse with a form, fill and seal machine are also possible. For example,the product settler can be in the form of an object such as a rod thatis positioned and actuated to intermittently impact a partially formedpackage and thereby settle product in the package. In some embodiments,the object can provide settling by contacting the partially formedpackage on one and only one face. In some embodiments, the objectimpacts the partially formed package more than 300 times per minute. Insome embodiments, the object impacts the partially formed package morethan 600 times per minute.

Furthermore, while the steps for particular embodiments of the inventionhave been described herein, a person skilled in the art would understandfrom the disclosure that the steps can be modified. For example, asappropriate, steps can occur at different times, steps can occursimultaneously or sequentially, the order of steps can be swapped orvaried, certain steps can overlap even if they start at different times,and steps can be added or removed.

While this invention is particularly shown and described herein withreference to preferred embodiments, it will be understood by thoseskilled in the art that various changes in form and detail can be madetherein without departing from the spirit and scope of the invention.The inventors expect skilled artisans to employ such variations asappropriate, and the inventors intend the invention to be practicedotherwise than as specifically described herein. Accordingly, thisinvention includes all modifications and equivalents of the subjectmatter recited in the claims appended hereto as permitted by applicablelaw. Moreover, any combination of the elements described herein, in allpossible variations thereof, is encompassed by the invention unlessotherwise indicated herein or otherwise clearly contradicted by context.For example, various advantages of the invention can still be realizedif additional elements are added to provide additional advantages or ifcertain elements are omitted because a particular feature is unnecessaryor undesirable for a given application.

ADDITIONAL DISCLOSURE

The following clauses are offered as further description of thedisclosed invention.

1. A method for settling a product in a package made on a form, fill andseal machine, the method comprising the steps:

-   -   a. providing a package material on a product conduit of a form,        fill and seal machine;    -   c. forming a first end seal on the package material to form a        partially formed package;    -   d. filling the partially formed package with the product (e.g.,        with a desired amount of product or with an amount of product        provides the package with a desired amount of headspace); and    -   e. settling the product in the partially formed package while        continuously conveying the package material along the product        conduit.        2. The method of any preceding clause further comprising the        step:    -   f. forming a second end seal on the partially formed package to        form a package from the partially formed package.        3. The method of any preceding clause further comprising the        step:    -   b. sealing the package material to form a longitudinal seal.        4. The method of clause 3, wherein the first end seal is        approximately perpendicular to the longitudinal seal, or wherein        the first end seal is within 30, 25, 20, 15, 10, 5 degrees of        perpendicular to the longitudinal seal.        5. The method of any preceding clause, further comprising the        step:    -   directing a gas into the partially formed package.        6. The method of clause 5, wherein the gas is directed into the        partially formed package as a first jet of gas.        7. The method of clause 5 or 6, wherein the gas pressurizes an        interior of the partially formed package.        8. The method of any preceding clause, wherein the settling step        further comprises the steps:    -   pressurizing an interior of the partially formed package to        provide resistance; and    -   intermittently contacting the partially formed package to move        the partially formed package, thereby moving the product.        9. The method of any preceding clause, wherein the settling step        further comprises the steps:

rotating a paddle wheel comprising a paddle; and

intermittently rotating the paddle into contact with the partiallyformed package, thereby moving the product while the product is insidethe partially formed package.

10. The method of clause 9,

-   -   wherein the method is characterized by a feature selected from        the group consisting of:        -   wherein the paddle (or each of a plurality of paddles)            comprises at least one aperture (e.g., slot or hole);        -   wherein the paddle contacts the package once per rotation of            the paddle;    -   wherein a flow of air created by the rotation of the paddle (as        opposed to contact with the paddle) pushes the package material        by no more than 1, 0.9, 0.8, 0.7, 0.6, 0.5, 0.4, 0.3, 0.2 or 0.1        inches from a hanging reference position (e.g., a first        position) wherein the hanging reference position is a position        of the package material when the package material hangs under        the force of gravity and any force of internal pressure (e.g.,        from a source of pressurized gas (e.g., compressor)) and when        the product settler is inactive and out of contact with the        package material;    -   wherein after impact by a paddle (or each of a plurality of        paddles) the package material returns to a hanging reference        position, wherein the hanging reference position is a position        of the package material when the package material hangs under        the force of gravity and any force of internal pressure (e.g.,        from a source of pressurized gas (e.g., compressor)) and when        the product settler is inactive and out of contact with the        package material; and    -   a combination thereof.        11. The method of clause 9 or 10, wherein an actuator rotates        the paddle and stops the paddle in a desired position.        12. The method of clause 11, wherein the actuator is        characterized by a feature selected from the following group of        features:    -   the actuator is a motor;    -   the actuator is a stepper motor;    -   the actuator is programmable to change (e.g., increase or        decrease) oscillatory or rotational speed of the paddle at a        desired rate;    -   the actuator is programmable to control acceleration (e.g.,        increasing or decreasing rotational speed) of the paddle wheel;    -   the actuator is programmable to select the position of the        paddle when the paddle stops; and    -   a combination thereof.        13. The method of claim 11 or 12, wherein the method further        comprises a step selected from the group consisting of:    -   using the actuator to change (e.g., increase or decrease) an        oscillatory or rotational speed of the paddle at a first desired        rate by changing an oscillatory or rotational speed of a        component of the actuator (e.g., rotor, drive shaft, piston,        etc.), optionally wherein the component of the actuator is        linked (e.g., mechanically, electromagnetically, or a        combination thereof) with the paddle, and optionally using the        actuator to change the oscillatory or rotational speed of the        paddle at a second desired rate by changing the oscillatory or        rotational speed of the component of the actuator oscillates or        rotates;    -   using the actuator to control acceleration (e.g., increasing or        decreasing rotational or oscillatory speed) of the paddle, the        plurality of paddles, the paddle wheel, or a combination        thereof;    -   using the actuator to stop the paddle (or each of the plurality        of paddles) in a desired position (e.g., out of a path of the        package material or out of contact with the package material);        and    -   a combination thereof.        14. The method of any preceding clause, wherein the settling        step further comprises:    -   using the product settler to provide the package material with        an amplitude of vibration equal to at least and/or no more than        3, 2.5, 2, 1, 0.9, 0.8, 0.7, 0.6, 0.5, 0.4, 0.3, 0.2, 0.1        inches.        15. The method of any of clauses 9-14, wherein the paddle does        not bend by more than a specified bend tolerance during use        (e.g., as a result of contact with the package material),        wherein the specified bend tolerance is an angle measured in a        plane that is perpendicular to the axis of rotation of the        paddle wheel, wherein the specified bend tolerance is no more        than 30, 20, 15, 10, 5, 4, 3, 2, or 1 degrees, and wherein the        specified bend tolerance is measured for a leading surface of        the paddle and from a proximal reference line to a distal        reference line, wherein the proximal reference line is parallel        to a proximal end of the paddle (e.g., end closer to an axis of        rotation of the paddle wheel) and the distal reference line is        parallel to a distal end of the paddle (e.g., end further from        an axis of rotation of the paddle wheel).        16. The method of any preceding clause wherein the package        material is a film.        17. An improved continuous motion form, fill and seal machine,        said machine comprising a product conduit, a conveyor, and seal        jaws; wherein the conveyor is positioned to convey a package        material that is wrapped around the product conduit; wherein the        conveyor moves the package material along the product conduit;        wherein the seal jaws are positioned adjacent to opposite        portions of the package material to form a first end seal on the        package material, thereby forming a partially formed package;        wherein the product conduit is positioned so that a product        passing through the product conduit will enter the partially        formed package after exiting the product conduit; and wherein        the product conduit is positioned above the seal jaws; wherein        the improvement comprises:    -   a product settler comprising a first object positioned to cause        an impact against the package material;    -   wherein the impact agitates the package material and settles the        product from an unsettled height to a settled height while the        machine continuously conveys the package material along the        product conduit.        18. The machine of any preceding clause, wherein the machine        comprises a source of pressurized gas.        19. The machine of clause 18, wherein the machine comprises a        nozzle and/or conduit to direct the pressurized gas into the        package material.        20. The machine of any preceding clause, wherein the product        settler comprises a controller to set a number of impacts per        minute that the first object causes on the package material.        21. The machine of any preceding clause, wherein the product        settler comprises a positional sensor to determine a position of        the first object.        22. The machine of any preceding clause, wherein the impact        occurs on one and only one face of the partially formed package.        23. The machine of any preceding clause, wherein the first        object directly contacts the package material to cause the        impact.        24. The machine of any preceding clause, wherein the impact        against the package material occurs below the product conduit        and above the unsettled height.        25. The machine of any preceding clause, wherein the product        settler comprises a motor with sufficiently low torque that if        the motor is deactivated (e.g., stopped, turned off, disengaged)        while the first object is in contact with the package material,        as the package material is conveyed, the package material will        push the first object out of a path of the package material.        26. The machine of any preceding clause, wherein the product        settler is modular.        27. The machine of any preceding clause, wherein the product        settler comprises a frame that spatially fixes the product        settler in relation to a path of the package material.        28. The machine of any preceding clause, wherein the product        settler comprises a first adjustable mount to move the product        settler in a first direction.        29. The machine of any preceding clause, wherein the settler is        positioned so that, as the first object moves into contact with        the package material, the first object will first contact the        package material at a first point that is a second distance        below the product conduit.        30. The machine of any preceding clause, wherein the product        settler is positioned adjacent to the package material so that,        as the first object moves into contact with the package        material, the first object will contact the package material        below the product conduit and above the unsettled height of the        product.        31. The machine of any preceding clause:    -   wherein the seal jaws comprise a first seal jaw and a second        seal jaw;    -   wherein the first seal jaw rotates around a first axis of        rotation;    -   wherein the second seal jaw rotates around a second axis of        rotation;    -   wherein the first seal jaw, the first axis of rotation, the        second seal jaw and the second axis of rotation are positioned        so that, as the first seal jaw and the second seal jaw rotate,        the first seal jaw and the second seal jaw come together to form        the first end seal.        32. The machine of any preceding clause:    -   wherein the seal jaws comprise a third seal jaw and a fourth        seal jaw;    -   wherein the third seal jaw rotates around a first axis of        rotation;    -   wherein the fourth seal jaw rotates around a second axis of        rotation;    -   wherein the third seal jaw, the first axis of rotation, the        fourth seal jaw and the second axis of rotation are positioned        so that, as the third seal jaw and the fourth seal jaw rotate,        the third seal and the fourth seal jaw come together to form a        second end seal on the package material thereby forming a        package.        33. The machine of any preceding clause, wherein the package        material is a film.        34. The machine of any preceding clause, wherein the machine is        a vertical form, fill and seal machine.        35. The machine of any preceding clause:    -   wherein the first object is a rotatable paddle wheel;    -   wherein the paddle wheel comprises a paddle; and    -   wherein the paddle is positioned so that, as the paddle wheel        rotates, the paddle causes agitation of the package material and        thereby settles the product.        36. The machine of clause 35, wherein the length of the paddle        (as measured radially outward from an axis of rotation of the        paddle wheel to a distal end of the paddle wheel) is (i) long        enough to enable to the paddle to reach the package material and        past the package material by at least and/or no more than 0.1,        0.2, 0.3, 0.4, 0.5, 0.75, 1, 1.5, or 2 inches, or (ii) is at        least and/or no more than 0.1, 0.2, 0.3, 0.4, 0.5, 0.75, 1, 1.5,        2, 3 or 4 inches, or (iii) a combination thereof.        37. The machine of clause 35 or 36, wherein the product settler        comprises:    -   a motor comprising a rotor, wherein the motor causes the rotor        to rotate, optionally, wherein the rotor is or is not an axle        for the paddle wheel, and optionally wherein an axis of rotation        for the rotor and an axis of rotation for the paddle wheel are        or are not concentric.        38. The machine of clause 37,    -   optionally, wherein the rotor is straight from the motor and        along the portion of the rotor that acts as the axle for the        paddle wheel;    -   optionally, wherein no force transfer components (e.g., gears,        belt, etc.) apart from the rotor are used between the motor and        the paddle wheel;    -   optionally wherein the product settler occupies less space than        a reference product settler that comprises the force transfer        components;    -   optionally, wherein the motor, the rotor, the paddle wheel or a        combination thereof fit (e.g, during operation) within a        reference cylinder, wherein the reference cylinder has a        reference cylinder radius of no more than and/or at least 8, 7,        6, 5, 4, 3, 2, 1.5, 1 or 0.5 inches, and wherein the reference        cylinder has a reference cylinder height of no more than and/or        at least 24, 20, 18, 16, 15, 14, 13, 12, 11, 10, 9, 8, 7, 6, 5,        4, 3, or 2 inches;    -   optionally, wherein an axis of rotation for the rotor of the        motor and an axis of rotation for the paddle wheel are        concentric, and wherein a reference motor cylinder has a central        axis that is concentric with the axis of rotation for the rotor        and wherein the radius of the reference motor cylinder is the        minimum radius that results in the reference motor cylinder        being large enough to fully contain the motor (e.g., with no        portion of the motor protruding outside the reference motor        cylinder), and wherein a reference paddle wheel cylinder has a        central axis that is concentric with the axis of rotation for        the rotor and wherein the radius of the reference paddle wheel        cylinder is the minimum radius that results in the reference        paddle wheel cylinder being large enough to fully contain the        paddle wheel (e.g., with no portion of the paddle wheel        protruding outside the reference paddle wheel cylinder), and        optionally wherein the reference paddle wheel cylinder is at        least as large or larger than the reference motor cylinder or        alternatively, or optionally wherein the reference motor        cylinder is at least as large or larger than the reference        paddle wheel cylinder;    -   optionally wherein the motor, the rotor, the paddle wheel or a        combination thereof fit (e.g., during operation) within a volume        equal to no more than and/or at least 2, 1.9, 1.8, 1.7, 1.6,        1.5, 1.4, 1.3, 1.2, 1.1, 1.0, 0.9, 0.8, 0.7, 0.6, 0.6, 0.4, 0.3,        0.2, 0.1, 0.5, 0.1, 0.05, 0.04 cubic feet; or    -   a combination thereof.        39. The machine of any of clauses 37-38, wherein the motor is        characterized by a feature selected from the following group of        features:    -   the motor is a stepper motor;    -   the motor can be programmed to change (e.g., increase or        decrease) oscillatory or rotational speed of the first object at        a desired rate;    -   the motor can be programmed to provide more control over        acceleration (e.g., increasing or decreasing rotational or        oscillatory speed) of the at least one object (e.g., paddle) or        paddle wheel, to enable selecting the position of the at least        one object when it stops; and    -   a combination thereof.        40. The machine of any one of clauses 35-39, wherein the paddle        wheel comprises a plurality of paddles (e.g., no more than        and/or at least four, three, or two paddles);    -   optionally, wherein the plurality of paddles are spaced around a        paddle wheel to provide a paddle spacing angle between each set        of two adjacent paddles in the plurality of paddles;    -   optionally, wherein the paddle spacing angle differs from a        common angle by no more than a specified tolerance, wherein the        common angle is defined to equal 360 degrees divided by the        number of paddles in the plurality of paddles, wherein the        specified tolerance has a magnitude of no more than 45, 30, 25,        20, 15, 10, 5, 4, 3, 2 or 1 degrees.        41. The machine of any one of clauses 35-40, wherein the paddle        (or each of a plurality of paddles) comprises at least one        aperture;    -   optionally, wherein the at least one aperture is configured:        -   to avoid creating a flow of air that pushes the package            material away from the paddle,        -   to avoid creating a flow of air that pushes the package            material sufficiently far away from the paddle during a            rotation of the paddle that the paddle does not contact the            package material during the rotation,        -   to avoid creating a flow of air that pushes the package            material by more than 1, 0.9, 0.8, 0.7, 0.6, 0.5, 0.4, 0.3,            0.2 or 0.1 inches from a hanging reference position in which            the package material hangs under the force of gravity and            any force of internal pressure (e.g., from a source of            pressurized gas),        -   to avoid creating a flow of air that prevents the package            material from returning to a hanging reference position            under the force of gravity and any force of internal            pressure (e.g., from a source of pressurized gas),        -   so that the at least one aperture (e.g., the aperture or the            plurality of apertures) has a total aperture surface area            equal to at least 30, 40, 50, 60, 70, 80, 85, 90, 95, 96,            97, 98, or 99% of the surface area of a leading surface of            the paddle 320 a; or        -   a combination thereof.            42. The machine of any one of clauses 35-41:    -   wherein the package material comprises an impact face;    -   wherein the impact face is adjacent to the product settler;    -   wherein, when the impact face of the package material hangs        under a force of gravity, the impact face defines a first        position;    -   wherein the settler is positioned so that as the paddle wheel        rotates, a first tip of the paddle will reach past (e.g.,        horizontally) the first position by a first distance; and    -   wherein the first distance reaches a maximum of at least and/or        no more than 0.25, 0.5, 1, 1.5, 2, 2.5 or 3 inches while the        paddle wheel rotates.        43. The machine of any one of clauses 35-42, wherein the paddle        wheel comprises a plurality of paddles.        44. The machine of any preceding clause, wherein the first        object is characterized by at least one of the following        features:    -   the first object (e.g., paddle) is rigid;    -   the first object does not bend by more than a specified bend        tolerance during use (e.g., as a result of contact with the        package material), wherein the specified bend tolerance is no        more than 30, 20, 15, 10, 5, 4, 3, 2, or 1 degrees, wherein the        specified bend tolerance is measured from a proximal reference        line to a distal reference line and measured in a plane        perpendicular to the axis of rotation of the paddle wheel,        wherein the proximal reference line is parallel to a proximal        end of the first object (e.g., end closer to an axis of rotation        of the paddle wheel), and wherein the distal reference line is        parallel to a distal end of the first object (e.g., end further        from an axis of rotation of the paddle wheel); and    -   a combination thereof.        45. The machine of any preceding clause, wherein the first        object comprises at least one aperture (e.g., to enable passage        of air through the first object, to avoid a fan-like effect in        which the first object causes air to move into contact with the        package material and push the package material away from the        first object).        46. The machine of any preceding clause, wherein the first        object is made from a material selected from the group        consisting of metal, alloy, steel, polymer, plastic, resin,        rubber and wood.        47. A method for settling a product in a partially formed        package, the method comprising the steps:    -   a. providing a partially formed package;    -   b. filling the partially formed package with a product; and    -   c. settling the product in the partially formed package;    -   wherein the settling step comprises:        -   rotating a paddle wheel comprising at least one paddle            against the partially formed package.            48. The method of any preceding clause, further comprising            the step:    -   g. closing the partially formed package to form a package.        49. The method of any preceding clause, further comprising the        step:    -   h. directing a pressurized gas into the partially formed        package.        50. The method of any preceding clause, wherein the paddle wheel        rotates intermittently.        51. The method of any preceding clause, wherein the paddle wheel        rotates continuously.        52. The method of any preceding clause, wherein the at least one        paddle intermittently contacts the partially formed package.        53. The method of any preceding clause, wherein the partially        formed package is provided on a form, fill and seal machine that        intermittently conveys a package material along a product        conduit.        54. The method of any preceding clause, wherein the partially        formed package is provided on a form, fill and seal machine that        continuously conveys a package material along a product conduit.        55. The method of any preceding clause, wherein the providing        step further comprises the steps:    -   i. providing a package material on a product conduit of a form,        fill and seal machine;    -   iii. forming a first end seal on the package material to form        the partially formed package.        56. The method of clause 55, wherein the providing step further        comprises the step:    -   ii. sealing the package material to form a longitudinal seal.        57. The method of clause 55 or 56, further comprising the step:    -   f. forming a second end seal on the partially formed package to        form a package from the partially formed package.        58. The method of any preceding clause, further comprising the        step:    -   e. settling the product in the partially formed package while        continuously conveying a package material along a product        conduit.        59. The method of clause 56, 57 or 58:    -   wherein the first end seal is approximately perpendicular to the        longitudinal seal.        60. An apparatus comprising an improved product settler for        settling product in a partially formed package; wherein the        improved product settler comprises:    -   a paddle wheel;    -   wherein the paddle wheel comprises at least one paddle that is        positioned to cause an impact against the partially formed        package;    -   wherein the impact agitates the partially formed package and        thereby settles the product.        61. The apparatus of any preceding clause, wherein the apparatus        further comprises a source of pressurized gas.        62. The apparatus of clause 61, wherein the apparatus comprises        a conduit (e.g., nozzle) to direct the pressurized gas into the        partially formed package.        63. The apparatus of any preceding clause, wherein the product        settler comprises a controller to set a number of impacts per        minute that the paddle wheel causes on the partially formed        package.        64. The apparatus of any preceding clause, wherein the product        settler comprises a positional sensor to determine the position        of the paddle wheel.        65. The apparatus of any preceding clause, wherein the apparatus        comprises a positional sensor to determine the position of the        paddle wheel.        66. The apparatus of any preceding clause, wherein the impact        occurs on one and only one face of the partially formed package.        67. The apparatus of any preceding clause, wherein the paddle        wheel directly contacts the partially formed package to cause        the impact.        68. The apparatus of any preceding clause, wherein the product        settler comprises a motor with sufficiently low torque that if        the motor turns off while the paddle wheel is in contact with        the partially formed package, as the partially formed package is        conveyed, the partially formed package will push the paddle        wheel out of a path of the partially formed package.        69. The apparatus of any preceding clause, wherein the product        settler is modular.        70. The apparatus of any preceding clause, wherein the product        settler comprises a frame that spatially fixes the product        settler in relation to a path of the partially formed package.        71. The apparatus of any preceding clause, wherein the product        settler comprises a first adjustable mount to move the product        settler in a first direction.        72. The apparatus of any preceding clause, wherein the paddle        wheel comprises a plurality of paddles.        73. The apparatus of any preceding clause, wherein the apparatus        comprises a form, fill and seal machine.        74. The apparatus of any preceding clause, wherein the apparatus        comprises a form, fill and seal machine that advances film        continuously along a product conduit.        75. An apparatus comprising at least one element selected from        any of the preceding apparatus clauses, machine clauses, or a        combination thereof.        76. A method comprising at least one element selected from any        of the preceding method clauses, apparatus clauses, machine        clauses or a combination thereof.        77. A method comprising elements selected from any of the        preceding method clauses or a combination thereof, optionally,        wherein the method comprises the apparatus of any of the        preceding clauses, the machine of any of the preceding clauses,        or a combination thereof, optionally, wherein the method is a        method of using an apparatus or machine.

What is claimed:
 1. A method for settling a product in a package made ona form, fill and seal machine, the method comprising the steps: a.providing a package material on a product conduit of a form, fill andseal machine; c. forming a first end seal on the package material toform a partially formed package; d. filling the partially formed packagewith the product; and e. settling the product in the partially formedpackage while continuously conveying the package material along theproduct conduit.
 2. The method of claim 1 further comprising a stepselected from the group consisting of: b. sealing the package materialto form a longitudinal seal; f. forming a second end seal on thepartially formed package to form a package from the partially formedpackage; and a combination thereof.
 3. The method of claim 1, whereinthe settling step further comprises the steps: pressurizing an interiorof the partially formed package to provide resistance; andintermittently contacting the partially formed package to move thepartially formed package, thereby moving the product.
 4. The method ofclaim 1, wherein the settling step further comprises the steps: rotatinga paddle wheel comprising a paddle; intermittently rotating the paddleinto contact with the partially formed package, thereby moving theproduct while the product is inside the partially formed package.
 5. Themethod of claim 4, wherein an actuator rotates the paddle and stops thepaddle in a desired position.
 6. The method of claim 5, wherein themethod further comprises: using the actuator to change a rotationalspeed of the paddle at a first desired rate by changing a rotationalspeed of a component of the actuator, wherein the component of theactuator is linked to the paddle.
 7. The method of claim 1, wherein thesettling step further comprises: using a product settler to provide thepackage material with an amplitude of vibration of 0.1 to 3 inches. 8.The method of claim 4, wherein the paddle contacts the package once perrotation of the paddle.
 9. The method of claim 4, wherein the paddledoes not bend by more than a specified bend tolerance during use,wherein the specified bend tolerance is an angle measured in a planethat is perpendicular to the axis of rotation of the paddle wheel,wherein the specified bend tolerance is no more than 30 degrees, andwherein the specified bend tolerance is measured on a leading surface ofthe paddle and from a proximal reference line to a distal referenceline, wherein the proximal reference line is parallel to a proximal endof the paddle, and wherein the distal reference line is parallel to adistal end of the paddle.
 10. An improved continuous motion form, filland seal machine, said machine comprising a product conduit, a conveyor,and seal jaws; wherein the conveyor is positioned to convey a packagematerial that is wrapped around the product conduit; wherein theconveyor moves the package material along the product conduit; whereinthe seal jaws are positioned adjacent to opposite portions of thepackage material to form a first end seal on the package material,thereby forming a partially formed package; wherein the product conduitis positioned so that a product passing through the product conduit willenter the partially formed package after exiting the product conduit;and wherein the product conduit is positioned above the seal jaws;wherein the improvement comprises: a product settler comprising a firstobject positioned to cause an impact against the package material;wherein the impact agitates the package material and settles the productfrom an unsettled height to a settled height while the machinecontinuously conveys the package material along the product conduit. 11.The machine of claim 10, wherein the machine comprises a source ofpressurized gas, and a conduit to direct the pressurized gas into thepackage material.
 12. The machine of claim 10, wherein the impact occurson one and only one face of the partially formed package.
 13. Themachine of claim 10, wherein the impact against the package materialoccurs below the product conduit and above the unsettled height.
 14. Themachine of claim 10, wherein the product settler comprises a motor withsufficiently low torque so that if the motor is deactivated while thefirst object is in contact with the package material, as the packagematerial is conveyed, the package material will push the first objectout of a path of the package material.
 15. The machine of claim 10:wherein the first object is a rotatable paddle wheel; wherein the paddlewheel comprises a paddle; and wherein the paddle is positioned so that,as the paddle wheel rotates, the paddle causes agitation of the packagematerial and thereby settles the product.
 16. The machine of claim 15:wherein the package material comprises an impact face; wherein theimpact face is adjacent to the product settler; wherein, when the impactface of the package material hangs under a force of gravity, the impactface defines a first position; wherein the product settler is positionedso that as the paddle wheel rotates, a first tip of the paddle willreach past the first position by a first distance; and wherein the firstdistance reaches a maximum of 0.25 to 3 inches while the paddle wheelrotates.
 17. The machine of claim 15, wherein the product settlercomprises: a motor comprising a rotor; wherein the motor causes therotor to rotate; and wherein an axis of rotation for the rotor and anaxis of rotation for the paddle wheel are concentric.
 18. The machine ofclaim 17, wherein, in use, the motor, the rotor, and the paddle wheelfit within a reference cylinder, wherein the reference cylinder has areference cylinder radius of no more than 8 inches and a referencecylinder height of no more than 24 inches.
 19. The machine of claim 17,wherein the motor is a stepper motor.
 20. The machine of claim 15,wherein the paddle wheel comprises a plurality of paddles; wherein theplurality of paddles are spaced around a paddle wheel to provide apaddle spacing angle between each set of two adjacent paddles in theplurality of paddles; wherein the paddle spacing angle differs from acommon angle by no more than a specified tolerance; wherein the commonangle is defined to equal 360 degrees divided by the number of paddlesin the plurality of paddles; and wherein the specified tolerance has amagnitude of no more than 45 degrees.
 21. The machine of claim 15,wherein the paddle comprises at least one aperture; and wherein the atleast one aperture is configured so that the at least one aperture has atotal aperture surface area equal to at least 30% of the surface area ofa leading surface of the paddle.
 22. The machine of claim 10, whereinthe first object does not bend by more than a specified bend toleranceduring use; wherein the specified bend tolerance is no more than 30degrees; wherein the specified bend tolerance is measured from aproximal reference line to a distal reference line and measured in aplane perpendicular to the axis of rotation of the paddle wheel; whereinthe proximal reference line is parallel to a proximal end of the firstobject; and wherein the distal reference line is parallel to a distalend of the first object.
 23. The machine of claim 10, wherein the firstobject is made from a material selected from the group consisting ofmetal, alloy, steel, polymer, plastic, resin, rubber and wood.
 24. Themachine of claim 15, wherein the length of the paddle, as measuredradially outward from an axis of rotation of the paddle wheel to adistal end of the paddle: (i) is long enough to enable to the paddle toreach the package material and past the package material by at least 0.5inches, or (ii) is at least 0.5 inches.